UNITED  STATES 
ARTILLERY  AMMUNIT. 


UNITED  STATES 
ARTILLERY  AMMUNITION 


MUNITIONS   BOOKS 

COMPILED  BY 

THE    EDITORIAL   STAFF 

OF   THE 

AMERICAN    MACHINIST 


Manufacture  of  Artillery  Ammunition, 

759  pages,  6x9,  648  Illustrations $6 .00 

Shrapnel  and  Other  War  Material, 
92  pages,  8%  x  11)4,  Fully  Illustrated $1 .  50 

United  States  Artillery  Ammunition, 

97   pages,  8%  x  11>^,  Fully  Illustrated $2.00 


UNITED  STATES 
ARTILLERY  AMMUNITION 


3  TO  6  IN.  SHRAPNEL  SHELLS 
3  TO  6  IN.  HIGH  EXPLOSIVE  SHELLS 

AND 

THEIR  CARTRIDGE  CASES 


BY 

ETHAN  VIALL 

Managing  Editor  American  Machinist, 

Member  American  Society  op  Mechanical  Engineers, 

Member  Franklin  Institute 


First  Edition 


McGRAW-HILL  BOOK  COMPANY,  Inc. 
239  WEST  39TH  STREET.     NEW  YORK 


LONDON:  HILL  PUBLISHING  CO.,  Ltd. 

6  &  8  BOUVERIE  ST.,  E.  C. 

1917 


<^3 


Copyright,  1917,  by  the  McGraw-Hill  Book  Company,  Inc. 


FOREWORD 

X  (/organization  could  have  been  better  fitted 
than  the  American  Machinist  for  the  task  of  col- 
lecting and  presenting  the  manufacturing  methods 
of  our  arsenals.  The  average  reader  does  not 
realize  the  enormous  amount  of  detail  involved 
in  a  task  of  this  kind. 

The  American  Machinist  has  in  this  work 
demonstrated  its  public  spirit  and  patriotism. 

HOWARD  E.  COFFIN, 

Chairman  of  Munitions  Committee, 
Council  of  National  Defense. 


361955 


PREFACE 

The  purpose  of  publishing  this  material  at 
the  present  time  is  to  give  shop  men,  engineers 
and  manufacturers  an  accurate  knowledge  of 
the  sizes,  tools,  shop  work  and  gages  for  the 
more  commonly  used  United  States  shells  and 
cartridge  cases. 

While  a  large  part  of  the  detail  work  con- 
nected with  the  gathering  of  the  material  in- 
corporated in  this  book  has  fallen  to  my  share, 
it  is  to  the  staff  of  the  American  Machinist  as  a 
whole  that  the  real  credit  belongs,  as  each  mem- 
ber stood  ready  at  all  times  to  do  his  part  and 

more. 

ETHAN  VIALL. 

New  York, 
July,  1917. 


vi  i 


CONTENTS 

Page 

Foreword v 

Preface vii 

I 

3  in.  Common  Shrapnel 1 

II 

3  in.  Common  Shells  (High  Explosive) 26 

III 

3  in.  Naval  Shells 48 

IV 

3 . 8  to  6  in.  Shrapnel  and  High  Explosive  Shells 56 

V 

6  in.  Naval  Shells : 62 

VI 

3  to  6  in.  Cartridge  Cases 71 

Index 95 


IX 


The  United  States  3-in.  common  shrapnel,  familiarly     guncotton  also  acts  as  an  aid  to  ignition.    The  fuse  ma] 
known  as  a  15-pounder,  carries  a  charge  of  238  hexagon-     be  set  for  time  explosion,  or  it  will  explode  on  impact 


shaped  lead  balls,  0.5  in. 
at  their  largest  diameter 
and  0.45  in.  at  the  flats. 
Back  of  the  balls  is  a 
charge  of  1180  grains  of 
shrapnel  powder.  Screwed 
into  the  front  end  of  the 
projectile  is  a  combination 
fuse  communicating  with 
the     powder     chamber 

-I6°30' 


,<■ - 8.4S+0.03- ->\ 

!>8.0lt0.05"---n----—^ 

-60/ta03-^  -  %-08hO3"Stra/ght 


«*88fiSW£ 


>)  f-astaos" 


0.08  R  V"*  "this  forging  is  used  for 3  com  mm  shrapnel 
5" FA  high-explosive  shrapana '3"£hrhardt 
high-explosive  shrapnel  ' 

FIG.    1.       DIMENSIONED    FORGING    FOR    3-IN. 

COMMON  SHRAPNEL 


\ 


8.3  1 0.03 

5.58"±0.0Z"- ^V^fc  **""» 

§1  7\-t.s"  - 


OjS'AlJ^  ^° '.20  per  inch  U.S.  Standard  Thread 


0.12  Drill  after 
Assembling  Head 


'jJ*^h77777777JF77777Z^^ 


-Remove  sharp  Corner 
after  Case  is  finished 


View  showing  Case  when' 
Tracer  is  Used 


St" 

28;? 


The  dimensions  of  th( 
case  forging  are  given  ii 
Fig.  1.  These  forging! 
must  be  thoroughly  an 
nealed  and  pass  the  follow 
ing  physical  tests :  Elasti< 
limit,  60,000  lb.;  tensili 
strength,  95,000  lb. ;  elong 
ation,  not  less  than  15  pe: 
cent.;  contraction  not  lesi 


Stamp  with  006Z"(tA  Letters  and  §  ; 


'ofShrapnef-— 
Case,  Purchase  Order  Dateoflssue_ 


figures :-  Lot  N- 

Case,  Purchase  0r~„, 

of  P0.( fiscal  Year)  and  Initials  of 

Manufacturer    The  Stamping 

prescribed  maybe  stampecT/h  on 

Band,  if  also  stamped  on  Base  within 

the  Groove,  in  Lieu  of  Stamping  in  front 

FinishjC  Outside,  Rough  Inside  except  where  marked jC 

Give  the  Powder  Chamber  a  heavy  Coat  of  non-acid  Paint        forged  alloy  steel 
Sreat  care  should  be  taken  to  remove  all  Burrs,  sharp       Machine  from  Solid  or  hollow 
Corners  and  Scale.    Eccentricity  not  over  0.01*       *  forged%eel±00l'' 


\  0375-~*i-ffl<:'005'R.  _  „,'    '        . 

,uj/o    -uui  Base  of  Shrapnel 

reo.'ofMTep         when  Traceris  Used 


Modification  of  Rear  of  Projectile 
for  use  in  3"  Howitzer 


k7~ 


0.45;— ->f<- 

0.04  R. 


-  0.35 
^     0.05% 


35° 


Detail   of  Grooves 


FIG.    2.      DIMENSIONED    FINISHED    CASE 


Press  Metal  of 
Fuse  into  Notch, 
for  Locking 

/A 


Waterproof 
'Cover  Groove- 


MATRIX 
Resin  and  pure  white 
•'.  '9?!TJV.?fciciiNapthalene 


Center  of 
/Gravity 


STOPPER,  Dry  fibrous  Gun  Cotton.  Roll  tightly  info 
a  Cylinder  and  press  down  until  it  rests  on 
Shoulder  of  Diaphragm  and  is  about  I  Inch  long. 


Base  of  Shrapnel 
when  Tracer  is  used. 


I  Waterproof    ' '.  r~JU^Z2Z2ZZZZ^^Z^2. 
1  Cover         HE^FILLER  ^-Slightly moisten  these 

L* — 


Joints  with  Cosmolene    *^~ 

• --8.3- 

10.84---- 

FIG.   3.     DETAILS  OF  COMPLETE  PROJECTILE 


Jl X 

-^BASE  CHARGE 
_>1  Shrapnel  Powder 

10%  of  each  Lot  will  be 

->l  fitted  with  Tracer 


through  a  small  tube,  the  shrapnel  powder  being  held  in     than  30  per  cent.     The  only  requirement  as  to  chemica1 
place  by  means  of  a  small  plug  of  dry  guncotton.     This     composition  is  that  neither  the  sulphur  nor  phosphonu 

content  shall  exceed  0.045  per  cent. 


♦Copyright,  1917,  Hill  Publishing  Co. 


[1] 


FIGS.   4  TO   11.      VARIOUS  OPERATIONS   ON  3-IN.    COMMON  SHRAPNEL,   CASES 

-„  F18;  4— Centering  in  drilling-  machine.  Fig.  5 — Turn  body  on  lathe.  Fig.  6— Finish  outside  (without  tracer  support). 
&]&•  ,7~*Lmi,sh  ,?utslde.  (with  tracer  support).  Fig.  8 — Finish  interior  on  automatic.  Fig.  9 — Turning  the  bands. 
Fig.   10 — Hydraulic   testing  apparatus.      Fig.   11 — Tapping   for  head. 


|2| 


Former  used  on  Grinding  machine.        Fl  -  Former  No.  1. 
Fig.   12.     STANDARD  LATHE 


F2  -  Former 
TOOLS  FOR 


No.  2.        H  -  High  speed  steel.        C  -  Carbon  steel. 
GENERAL  SHOP   USE 


[3] 


OPERATION  1.  CENTERING 
Transformation — Fig-.  13.  Machine  Used — Drilling-  machine, 
Fig.  4.  Number  of  Operators  per  Machine — One.  Work-Hold- 
ing Devices— Arbor,  Fig.  14.  Tool-Holding  Devices — Drill 
chuck.  Cutting  Tools — No.  42  combination  center  drill.  Cut 
Data — 350  r.p.m.  Production — 1200  per  8  hr.  Note — A  little 
red  lead  is  used  where  drilled. 

OPERATION  2.     TURN  BODY 

Transformation — Fig.  15.  Machine  Used — Le  Blond  17-in. 
lathe,  Fig.  5.  Number  of  Machines  per  Operator — Three. 
Work-Holding  Devices — Centering  chuck,  Fig.  16.  Cutting 
Tools — Left-hand  turning  tool,  Fig.  12.  Number  of  Cuts — One. 
Cut  Data — 50  ft.  surface  speed;  60  r.p.m.;  0.040-in.  feed.  Aver- 
age Life  of  Tool  Between  Grindings — 15  to  20  cases.  Gages 
— Length  from  base  to  bourrelet,  Fig.  17;  combination  maxi- 
mum and  minimum  snap,  Fig.  18;  maximum,  rear  of  band 
ring.  Fig.  19;  minimum  rear  of  band  ring,  Fig.  20.  Production 
— 250  per  8  hr.  Note — Speed  given  is  maximum,  as  lower  speed 
is  used  on  harder  cases. 

OPERATION  3.     FINISH  OUTSIDE   (CASE  WITHOUT 
TRACER   SUPPORT) 

Transformation — Fig.  21.  Machine  Used — Potter  &  John- 
ston  automatic,   Fig.    6.     Number   of  Machines   per  Operator — 


Without 
Night 

Tracer 

Support^ 

FIG.  13 


With  Night 
TracerSuppi 


1?„}S  n  r-Pm;;  fast  speed  and  feed  used  for  knurl  and  end 
work.  Coolant— Zurn  cutting  oil.  Special  Fixtures— Internal 
split  collet;  bushing  for  collet,  Fig.  25.  Gages— Maximum  and 
minimum  width  of  band  seat,  Fig.  26;  position  of  crimping 
grooves,  Fig  27;  combination  snap,  diameter  of  band  seat, 
Fl?-^8;^lck,ness  of  base  and  test  piece,  Fig.  29;  position  and 
width  of  band  seat,  Fig.  30.     Production— 300  per  8  hr. 

OPERATION  3-A.     FINISH  OUTSIDE   (CASE  WITH 
TRACER   SUPPORT)  ™       a 

Transformation — Fig.   31.     Machine  Used — Fig.   7.     Cutting 

£?°ls,TFMC\ngr  ™-'  Fie-  I2-"  Gages— Combination  sheet  gag* 
Fig.  33.  Note— This  operation  is  exactly  the  same  as  operation 
3,   except  for  different  facing  tool  and  one  gage. 

OPERATION  4.      FINISH   INTERIOR    (AND  BOURRELET 

WHEN   CASES   ARE    FINISHED   AT    FRANKFORD 

ARSENAL) 

Transformation — Fig.    34.      Machine   Used— Potter   &   John- 
ston automatic,  Figs.  8  and  9.     Number  of  Machines  per  Oper- 


Bushing 
0l"R,.T00L  STEEL(Harden) 


Q562"(i)TapStd  1.75' Deep 


05,Drilh 
I  Deep 
Stamp  Name  of  Shrapnel, 
Part,  Operation,  Place  of 
Manufacture,  and  Date-Year 
OPERATION  1 


FI6. 14 


FIG.  15 

^V0.046 


^fKVfl^   h --W5-. ,--.->WM37".-.>I     Lo.575*        * "eoMeD  STEEL 


.& 


oM 


Q4375'4  %h.QZ5-,.75">i     V-OWS" 


$    Q.I(M-   0%^%^7h 


:^-o.5"  I* 

7?.|<. ZZ5 

U.SStandard   &      S 


-7-"- 


Wedge 


FORGED  STEEL   0.I3R. 
Jaw 


MACH.  STEEL  (CaseHarden) 
Bushing 


0J87"(i") 


Y       » 

A 

& 

0.5"'h- 

#T 

L 

-8.6"— 

SAW  STEEL 


■733- 
FIG.I7 

2.4'- 

■2"- 


~-->|C/f5-': 

■---H 


JLY_u' 


•J 


t*0.375 


--2.375 

k-2.875"--— 

FORGED  STEEL 

Body 
-J  ^Adjusting 

&  tvj      Bolt  ->I0.625{< 

§  !  FIG.  16 

_  li 

I* -^;-;--H  2  Sheet  Brass  0.0508"    I    U~£+}|* Z41' H  2  Sheet  Brass,  00508" 

-->|  Wh/ck,  Name  Plates      KH375-->J   p—<f j  I- Thick,  Name  Plates 


^18 per  Inch,  t     & 
**  Right  Hand.  ££  S? 


-+-/J75'->|  U-f/25"  ^  -  \0W3^ 


i  -*- 


X~ 


Jaw  Screw 

FORGED  STEEL 


-H0.75U- 


■-/eo° * 

A  -£25, 6  Threads  per  Inch  for 
Reed  or  17- inch  L  e  Blond 
Lathe. 

A=2.875"5  Threads  per  Inch  for 
21-Inch  Le  Blond  Lathe. 

■2.8" 


H 

'J  k-//'->j<-//-->|  [• 


0.3r 

2,  Sheet  Brass, 
T-0.0508"Thick 
Name  Plate 


MACH.STEEL  (CaseHarden) 
FIG.  19 


\Standard  JL 
MACH.  STEEL     Countersunk  Head, 
(CaseHarden)    Bronze  Screws 
FIG.  20 

OPERATION  2 


>l(M5l<- 


I     o.06"M^-Case harden  6aging Surfaces 


_rcT 

MACH.STEEL 
FIG.  18 


[4] 


ator — Two.  Work-Holding  Devices — Split  chuck.  Tool-Hold- 
ing Devices — Rough  boring  bar;  finish  boring  bar;  tool  holder 
for  rough  bourrelet,  Fig.  35;  tool  post.  Cutting  Tools — Rough 
diaphragm-seat  cutter,  Fig.  36;  rough  boring  tool,  Fig.  36; 
rough  facing  tool,- Fig.  36;  finish  diaphragm-seat  cutter,  Fig. 
36;  finish  boring  tool,  Fig.  36;  finish  facing  tool,  Fig.  36;  cham- 
fering tool,  Fig.  36;  rough  outside  beveling  tool,  Fig.  37;  turn- 
ing tool  for  bourrelet,  Fig.  35;  square-nose  lathe  tool,  Fig.  12; 
finish  beveling  tool,  Fig.  37;  No.  2%  geometric  tap.     Cut  Data 


mmzz// 


«#w%w 


FIG.  31 


■1.625- 


3./25-"- 9* 

HIGH  SPEED  STEEL      , 
(Finish  XtOOrtlarcten) 
»f         FIG.  32 


JMDril/. 

IB    ■ 


\ 


>\QI2S  <■ 


FIG.  33 
OPERATION   3A 


— 50  ft.  surface  speed;  60  r.p.m.  working  speed;  35  r.p.m.  tap- 
ping speed;  20  ft.  surface  speed.  Coolant — Zurn  oil.  Gages — 
Maximum  and  minimum  depth  of  diaphragm  seat,  Fig.  38; 
combination  maximum  and  minimum  diameter  diaphragm  seat, 
Fig.  39;  combination  maximum  and  minimum  diameter  rear 
of  thread,  Fig.  40;  combination  length  of  case,  Fig.  41;  com- 
bination maximum  and  minimum  outside  diameter  and  taper 
of  mouth,  Fig.  42;  combination  snap,  bourrelet  diameter,  Fig. 
28;  maximum  ring,  bourrelet  diameter,  Fig.  43;  minimum  ring, 
bourrelet  diameter,  Fig.  44;  maximum  thread,  plug,  Fig.  45; 
minimum  thread,  plug,  Fig.  45;  maximum  and  minimum  diam- 
eter, powder  chamber,  Fig.  46.  Production — 180  per  8  hr. 
Note — Powder  chamber  is  machined  by  forgers. 

OPERATION    5.      ASSEMBLE    BAND 

Note — This  is  exactly  the  same  as  for  the  3-in.  common 
steel  shell,  except  that  only  1000-lb.  pressure  is  used,  on 
account  of  the  thinner  wall  of  the  case. 

OPERATION   6.     HYDRAULIC   TEST 

Number  of  Operators — One.  Description  of  Operation — 
Operator  places  case  in  fixture,  mouth  down,  pours  a  cup  of 
water  in  top  of  fixture  over  end  of  case,  turns  on  1000-lb. 
hydraulic  pressure -and  watches  water  and  case  for  bubbles 
or  jets.  Apparatus  and  Equipment  Used — Special  fixture,  Fig. 
47;  pressure  pump.     Production — 1200  per  8  hr. 

OPERATION  7.     TURN  BANDS 

Transformation — Fig.  48.  Machine  Used — Fig.  9.  Gages — 
Finished  band  profile  and  position,  Fig.  49.  Note — Operation 
same  as  for  3-in.  common  steel  shell. 

OPERATION   8.     TAP   FOR  NIGHT   TRACER 

Transformation— Fig.  50.  Machine  Used — Warner  &  Swasey 
turret  lathe,  Fig.  51.  Number  of  Operators  per  Machine — One 
Tool-Holding  Devices — Tap  holder,  drill  holder,  recessing-tool 
holder.  Fig.  52.  Cutting  Tools — Drill,  reamer,  Fig.  53; 
recessing  tool,  Fig.  54;  tap,  Fig.  55.  Cut  Data — 334  r.p.m. 
machinery  speed;  58  r.p.m.  tapping  speed.  Coolant — Zurn  oil. 
Gages — Combination  depth,  Fig.  56;  maximum  and  minimum 
thread,  plug,  Fig.  57.     Production — 185  per  8  hr. 


K- 4.0- -'H 

U 325"_ ^ua75$ 

^,„Jt         I  2,05'I.I25 
\r$~i6Z5r\:""*»  Filisterhead 
\05%p,m.  »pxr      screws\ 


<—  -/5"->K -S5-- 

*075'Wo.75^- 3.25"- >| 

05UOnSiZf.  t<~  1-25- ->\n 

Steel  Setscrew       *f62Si*Ml&  ,4,0j"Ho/es,  QS'lkep 

H — i — f^x 


0.5*1.125  Sfd 
Steel  Setscrew 


MACHINE  STEEL 

Finish J 't 0.005" 

Head 


MACHINE  STEEL 

Finish/ 1 0.005" 

Cap 


MACHINE  STEEL 

Finish/10005" 

Locknut 


MACHINE  STEEL 

Finish/ 1 0.005" 

Shank 


f-IS62"Cif->\  h- -30* 


FIG.22 
H 


k- — sir — *\ 

h-—3.l" 


FIG.2I 


Z±^Zf-l  I  til  I  tJ/TTTT 


I* — 7 &? -»r*- 0.5S"->\ 

"■0-55-%r0.55--^^mg^ 


''-•043700000' "-0.005"  \.®>  H/6H-SPEED  STEEL 

Finish /t0.005" Grind  Cutting  Edge 


Facing  Tool 


•OOS"*    35°  ■004lfR^  ~i'-0.059 

Dot  and  Dash          Tool  for  Cleveland  Automatic  Machine 
for  Angle  on 
'*ipf>  -Potter  &  Johnson  Auto...  ^l0fi    fc<sh< 20- 


y_j£ 


FIG.  2c 

90°->\04\<-  .0.005"/?. 

Detail  of  Knurls 


0.05">\\<-0.5">\ 


^> 


</.o'£  \    \+tol 

—i .y i 


MACHINE  STEEL 
Finish/ 10.0/" 


Stamp  Number  on  each  Piece 
Bushing  for  Collet  on  P  8c  J.  Automatic 
FIG.  25 


Q075 


HIGH-SPEED  STEEL  *  I  . 

Finish/ I0.005"and Harden   *<—-/95-—>i 
*0.000"  -0.003 

>QO00* 

'0^^^9^£M!£^^°MS"/?MCQ065" 


fC  ^o.o4"^v  otfifXd  ,- 

— >! 


-Q025  R: 
U- — 055 

h"" mfoi) 

Tool  for  Patter  8c  Johnson  Automatic 
FIG.  23 


H«Bft|  0062(0. 

— rwj' 

-0*025 Drill  j£,J 


Finish /tQOl'and  Harden 
HIGH-SPEED  STEEL 


Knurling  Tool 
FIG.  24 


Finish /I0.005nand  Harden 
SAW  STEEL 

Band  Seat  Width  and  Depth 

FIG.  26 


OPERATION  3 


[5] 


The  forgings  shall  be  free  cutting  and  readily  ma- 
chined. The  machinability  will  be  determined  by  turn- 
ing the  body  of  the  forgings,  as  received,  from  the  drawing 
diameter  to  a  diameter  of  3.062  in.  on  an  engine  lathe. 
This  turning  will  be  done  at  an  average  rate  of  14  shells 
per  hour  per  lathe,  and  at  this  speed  the  tool  consumption 
shall  not  exceed  one  tool  for  each  20  shells  turned  at  this 
rate. 

For  the  purpose  of  the  test  for  physical  qualities  and 
for  phosphorus  and  sulphur  content  the  forgings  will  be 
separated  into  lots  of  2000  each.  From  each  lot  of  2000 
the  inspector  will  select  six  forgings  for  physical  test, 
provided   that   additional   forgings   may   be   selected,   if 


is  shown  in  Fig.  3.     This  last  weighs  approximately  15 
lb.,  divided  as  follows : 


Lb. 

Case    5.89 

Band 0.15 

Washer    0.02 

Head 0.7 

Retainer    0.01 

Tube       (including-       inner 
tube)     0.09 


Lb. 

Balls    (238)     5.71 

Matrix    0.43 

Head  filler    0.07 

Diaphragm    0.48 

Base  charge 0.17 

Fuse    1.28 

Total    weight 15    ±0.15 


The  efficiency  equals  38  per  cent.,  and  the  velocity  of 
the  balls  must  be  not  less  than  260  ft.  per  sec. 

The  night  tracer  referred  to  is  a  small  device  placed 
on  10  per  cent,  of  the  projectiles,  for  use  at  night.  As 
the  shell  is  fired,  the  tracer  leaves  a  trail  of  fire  behind 
it,  commencing  a  few  seconds  after  it  leaves  the  muzzle 


(        f<—0/5--->H— 
-^-^■0.04"^ 


-0.3-r ->f<-— Ctf-s-k Q2" 

-is bfc/.  /,r  fy 


a 5 

Enlarged  View 


SAW  STEEL 
(Harden)  . 


§ 

¥ 

* 


A 


fc 


0.?5Drill(3\ 
"0.4R. 


f9 


<$ 


\Y-U9  Min>\ 
VI.2l"Max. 


_   Jt_ 


Q06?Qf$* 


f,FJnish=0.0.00S' 


FI6.27 


*\Q625fc-  0.625" 
•Diamond  Knurl  J^^fa  ~£\X" 

*> 

Yi  Y 


fj    &    §  r*-Q7&  root  steel 

ESsr 


Harden 


1     I 


x> 


\<0.75l\ 

□ 


"0.375 


Q?5n>\    ^-/.0"->\ 


TOOL  STEEL 

Finishfg.tQOf 

Harden 


-^ 


-L 


Stamp  Name  of  Shrapnel,  Part,  Operation, 

Dimension  gaged,  Place  of  Manufacture 

*  Date  (Year) 

.-,&. ...^ 

13  r  nsj 


!  435 

10  L 


±^L 
FI6.29 


DRILL  ROD 
Finish/ taOl" 
Gaging  Point  Finish 

Jg& Harden 


005  R/ 


Stamp  Name  of  Shrapnel,  Part,  Gage,  Dimensions  gaged,  Place  of 


Manufacture  &  Date  (Year) 
MACHINE . 


I 


0.06M |<-  1o    'Case  Harden  6aging  Surfaces'- 


kJb 


045\ 
t0.02 


_s 


PART 

A 

B 

C 

BAND  SEAT 

287 

2.86 

1.43 

BODY 

2.98 

2.965 

1.5 

BOURRELET 

2.99 

2.985 

1.5 

REAR  OF  BAND 

2.985 

2.975 

1.5 

FIG.  28 


-lLt 


qzs'r^k 


j— 


0.201 Drill-. 


I       U-0.55^ -12--— 

U. j0" 

SAW  STEEL 


0.5  > 


■X--I.O" 


<0.I2S" 


OPERATION  5 


FI6.30 


necessary,  to  obtain  not  less  than  one  forging  from  each 
lot  of  forgings  as  heat-treated.  Two  specimens  for  physi- 
cal test  will  be  taken  from  each  sample  forging  from  such 
parts  of  the  forging  as,  in  the  judgment  of  the  inspec- 
tor, will  best  indicate  the  uniformity  of  physical  qualities 
throughout.  The  contractor  shall  furnish  the  inspector 
with  an  analysis  of  each  heat  of  steel  used,  which  may  be 
verified  by  the  inspector  if  he  so  desires, 

Forgings  must  be  homogeneous  in  structure  and  free 
from  pipes  and  cracks.  Forgings  in  which  these  defects 
develop  during  machining  will  be  replaced  by  the  con- 
tractor. The  interior  of  the  forgings  must  be  smooth  and 
free  from  scale,  and  machining  must  be  resorted  to  in  or- 
der to  produce  this  result,  in  case  smoothness  is  not  ob- 
tained by  forging  under  the  press. 

A  finished  shrapnel  'case  with  all  dimensions  is  illus- 
trated in  Fig.  2,  and  a  completely  assembled  projectile 


of  the  gun  and  making  it  possible  to  follow  the  flight 
easily.  This  device  will  be  described  in  detail  elsewhere. 
The  sequence  of  operations  from  the  centering  of  the 
case  forging  to  the  final  crimping  on  of  the  waterproof 
cover  is  as  follows: 


l. 

2. 

3. 

3-A. 

4. 

5. 
6. 

7. 


Centering 

Turn  body 

Finish  outside  (case  without  tracer  support) 

Finish  outside  (case  with   tracer  support) 

Finish  interior    (and   bourrelet   when   cases   are   finished 

at   Frankford   Arsenal) 
Assemble  band 
Hydraulic  test 
Turn  bands 
Tap  for  night  tracer 

Head  (Bar  Stock) 
Machine  without  thread  and  countersink 
Countersink 
Turn  threads 
Mill  notches 
Crimp  in  washer 
Wash  in  hot  soda  watei 
Paint  inside 

Insert  retainer  and  fill  with  resin 
Face  off  resin 


[6] 


Diaphragm  (Forging) 

1.  Drill   and   counterbore 

2.  Heat-treatment 

3.  Remove  scale  from  counterbore 

4.  Grind  base 

5.  Paint  base 

6.  Assemble  tube 

Locking  Pins   (Bar  Stock) 
1,       Machine 


Assembling 

1.  Wash   case   in   hot   soda  water 

2.  Paint  interior 

3-A.     Assemble  tube  and  diaphragm 

3-B.     Fill  case 

3-C.     Compress  balls 

4.  Cut  out  surplus  resin 

5.  Moisten  threads  with  cosmoline,  assemble  head  to  case 

and  insert  inner  tube 

6.  Pin  head  to  case 


^^^^^^^^^^^ 


FIG.34A&B  A= Rouah\seats-beve' 'outside, 

B=  Finish  [machine  bourrelet       » 
(<— q" ^   ' machine  face         OOS^Y- 


■>\O6tC!0ff  k 
-0.01' 


FIG.  34  C 


■>|  K0./5" 


^-Z687"(z£)-^ 


FIG.  35 


TOOL  STEEL 

(flan/en) 


0.575  Tap.Std.^.yim^ 

□  □ 

□Dp 

■  /£J0>Jk 


,,  +00001 
■M6Z5&-0.005"  „ 


>\0.675'Uy%?»/0?5U  ^OS"/0005  Mouth  of  Case  Facing  Blade 
Stamp  name  ofshmcT  VJS-I.5-  *I  -^ 

and  warn,  of  cutter 
Diaphragm  Seat  Cutter 

HIGHSPEED 
yV.56Z^{§")  *»<!U*     STEEL 


■4K 


I0?\f 


±0.1" 


LZI 


T" 

<\| 


7.6" 

bfl  7'k- 


■1.5  R 
=£ — 


-A  Max. 


f 


I— ~ 


B  Min. 

SAW    STEEL 

FIG.  38 


a  t< y- 

5;  Mouth  of  Case 
Bevel  Blade 


-J 


FIG.  36 


OPERATION 

A 

B 

FIRST 

6.47 

'(544 

FINISHED 

6.44 

"64" 

J  ¥=10" 

k 37^5*  -- 

Mouth  of  Case 
Boring  Blade 

0.5" 

-  -A  Max. 


&5 


■J  SI 


n 


SAW    STEEL 


OPERATION      4 


u 


HIGH  SPEED      I 

1  K^/Zf'  Finish f ±0.0/,  Harden 
FIG.  37 


OPERATION 

A 

B 

FIRST 

<S# 

'AB* 

FINISHED 

<JJ5' 

«f7 

<5.25 


K-— -■■-BMin. 

Finish  y ±0.01.  Harden 


■>H  Stomp:  name  of  shrapnel  part, 
~"vd, place 


,.  »  .Finish gaging  surfaces    k 2.4" ^sof manufacture  anddc 

r" XZTKL'"T*\  ft  K?" *  U-oisils'sh** 


.  MACH.  STEEL      . 

Finish  S±0.0/r  0.W x/.5"Stee/Rin>i03& 

A-2.754"Max.-Z75"M/n.  ,       „. 

Stamp: nameof shrapnel, part,   U 5/25"+003'-'~ ■■---■■  ---"'"' 

size,  dimensions  gaaed, place of     Fir,  ^.k  '       *•*•"* 

manufacturer  ana"  date  (year)     r,v'*a 


1. 
1. 
1. 
1. 

1. 

2. 

,    3. 

3-A. 


Machine 
Machine 
Machine 
Punch 


Tube  (Central) 

Tube  (Inner) 

Retainer 

Washer    (Sheet  Steel) 

Making  Balls 


Casting  ingots 

Extruding   the   wire 

Forming  balls  on  special  machine 

Forming  balls  on  punch  press 


7.  Turn    bourrelet    (when    cases    are    finished    by    outside 

contract) 

8.  Groove  for  waterproof  cover 

9.  Paint  outside 

10.  Load  powder  charge 

11.  Brush  cosmoline  on  fuse  threads 

12.  Screw   in   fuse   and  lock 

13.  Set  fuse  to  safety  point 

14.  Crimp  on  waterproof  cover 

The  centering  is  a  simple  operation.     Following  this 
is  the  turning  of  the  body,  Fig.  5.    The  outside  finishing, 


7} 


Assembled    Views 


OS"R 


4"Stud,Wroughtlron    * 
^Pipe,Com.ta05n  \-jr-- 


QOS& 

FORGED  STEEL 

Finish /tOOl'  „ 

4Mach.SteelCdlanl?5  ■„-„■„-,  c 

DetaibonRod  +0005  Supporting    Rod 

HM2.2S"SteelPin 


flhrrad  : 


J 


steel     Top  Nut  /^/  Bo#omTuf 
■  --.jBtSf--.- 


force 


>l.5&Drill   . 

<,-■■  ms"- 

Bracket 

CASTIRON 

tQ05" 


perm. 


U/«|  8U.S.StdJhrdperin. 
Packing  Not  £J»§«. 

"k  i<-5"-->, 

&«£/#      vL,V I 

Thrdsperin.  --'  ^<ai       o 


037S  Drill 
0.2S"Deep 


6USJf^0TS^\<-m^  US" TOOL  STEEL 

\<—4:S"-..^      Finish/±  0.02  "Harden 
Adjusting  Screw 


^7^/>U   LEATHE/ttO.05 

Packing 


"I 


Bottom       Plcte 
FORGED  STEEL 
Finish  f 0.02" 

FIG.  47 


-2-L. 

0.5%pStud  O/V^^i 
05"  Deep-^   ->i/V    ^ 

u ?T3v 

AWSfl?  577Tfl. 

finish f±0.02r 

OS^SS^Steel  Rod.  Details 

onCrossBar 


Adjusting  Screw 
Nut 

MACH.  STEEL. 

Fmish/tO.02" 


Ream 
~>U S.Sid  Thrdsperin 


Cross     Bar 


N375H 


D.cb 


Wamff 


MACHINE  STEEL„ 
±0005* 3-0.31? 


Finish/ ±0.005*  3-0.312%^015'Filister- 
head  Steel  Screws  Standard 
Sib 


FIG.  50 


Drill  and  counterbore  for 
OMtklStd.FilJsterheadScrevr. 

U'i--\—-  A, 


'-o.ooz,\ 

«T      ■. 
§  iT.'    « 


s 


K 3.02' >| 

K ***- at  r^ffi 

IF 


-^ 


p-0/5B 


S!WO.l2S'OilHole 


/y  HIGH-SPEED  STEEL 


V.         niun-orccu  JICLL    - 

fZXpE?  /g(HardenJ  Finish/ 1Q0JB 
*     "1q 


y& 

FIG.53 


Guide  Block 


r&cZA=X/ 


lto 


Assembled  Views 

COLD-DRAWN  STEEL  Finish  J  ±0.005" 
0.I25"X025" Steel  Pin  Drive  .H  Q75V 

0.5l2WX0c2'Nut 

k—    </S25«f» H  0375:'oFoK 


^^^^0. 


025" Ream  ^counter- 
(Sink  for  Riveting 

•••-i--H- 


C\J       Jj../l/'        J  / 


T~ 


COLD-DRAWN  STEEL 
Finish  j ±0.005" 
Handle 


u  18  Threads  per  Inch 
"yUSStd.  Left  Hand 


K- — is 


-0.62-->\ 

-*1 

,    MACH.  STEEL 
t^fCase  Harden) 
?  Finish/* 0.01' 

Jff-r 


0.062%) 
COLD-DRAWN  STEEL 
Finish  J*  0.005" 
Handwheel 


FI6.55 


-j&— 


/A/g  ■*■ 

Stamp  Name  of  Shrapnel, 
t     Part,  Gage,  Dimensions 
•*\0.25\*--  gaged,  Place  of  Manufacture 

and  Date  (Year) 
FIG.  56 


T00LSTEEL(Hardenfjf%O00 
FinishjftQOl"      "—-0.001" 
18  Threads  per  Inch 
■USStd.  Left  Hand 


0.629"Max. 
0.625  Min. 


1/9, 

■0.156  R. 


S?, 


r^'-ro- 


0.I2SM  I 


4.  w 

.35.". ••-->] 

COLD-DRAWN  STEEL 

(Case  Harden) 

Finish/ ±0.01 

FIG.  57 


^7         ^ 


•^       Stamp  Name  of  Tracer,  fbrf. 
Place  of  Manufacture  and 
■>\  0.45*f-Date(YeaJ 


OPERATION  8 


V<7 

•>i  k-0flS5* 

H 1-7" 

HIGH-SPEED  STEEL      . 
(Harden)  Finish  J  ±0005 
Finish  Cutting  Edges /ft 
FIGS'" 


u/si+aooo'. 
w-0.002 


[8] 


FIGS.  59  TO  64.    VARIOUS  OPERATIONS  ON  THE  HEAD 

Fig.  59 — Machining  the  head.     Fig.  60 — Countersinking  head.     Fig.  61 — Crimping  in  washer.     Fig.  62 — inserting  retainer  and 
filling  with  resin.     Fig.  63 — Facing  off  resin.     Fig.  64 — Notching  head 


[9] 


shown  in  Figs.  6  and  7,  differs  principally  in  that  in 
the  latter  case  a  larger  place  has  to  be  left  on  the 
end  for  the  tracer  support,  a  special  tool  being  used. 
Finishing  the  interior,  Fig.  8,  is  done  on  both  Potter 
&  Johnston  and  Cleveland  machines,  as  shop  conditions 
at  the  time  or  as  the  sizes  of  the  various  shells  dictate. 


The  method  of  assembling  and  turning  the  copper 
rotating  bands  is  described  in  the  article  on  the  3-in. 
common  steel,  or  high-explosive,  shell.  The  making  of 
the  band  is  also  described  in  the  article. 

Standard  cutting  tools,  which  are  used  for  all  regular 
operations,  are  charted  in  Fig.  12  and  will  be  designated 

Crimping  Groove ;  ,/ 

14  Th'ds.per  Inch,  U.S.  Stct.^       \  I  ^JfOJh-ds.  perhch  USSfU 

J 


mach  srea.        ^L-i65 
finish  fOOlXase  Harden  "'"*■" 
Body 


MSS. 
\Thrdsper 

/  I6USSM 

Thrds.perin  v  mach  steel 

Stomp: name  ofmachmeand   ^shftOonase  Harden 

size.plaCe  of  manufacture  and  nZi.  \"  ^<"-D  DM  Wft  STEEL 

"'    Fir  7/1  hAa  finish fOOr 

FIG.74         Head  Scr> 


date  (year) 


HANDLE- 

(Mach  Steel) 

(Complete)    riG.75  Harden}  \5jST 

finish  ft  001"  l4US.Stdihrdperir!M5v 

O./sZof'Steelfin       Max.Diam  of  Fuze  Seat  Threuu 


[10] 


individually  only  by  their  common  names,  such  as  left- 
hand  lathe  tool.  The  dimensions  and  shape  of  the 
various  tools  can  be  quickly  obtained  by   reference   to 

the  chart. 

Work  on  the  Head 

Details  of  the  head  are  illustrated  in  Fig.  58.     This  is 
machined  from  bar  stock  on  automatic  machines,  as  shown 

oz'm",,  I 


in  Fig.  59,  each  operator  tending  three  machines.  The 
end  of  the  bar  is  drilled,  bored,  counterbored,  reamed, 
grooved,  faced  and  tapped  for  the  fuse.  At  the  same  time 
the  outside  is  formed  with  a  circle  tool.  The  tap  used 
is  of  the  collapsing  type,  oil  being  forced  to  the  work 
from  the  rear.  As  can  be  seen,  ample  provision  is  made 
for  supplying  all  the  tools  with  oil.  Owing  to  the  size 
of  the  piece,  the  number  of  operations  and  the  accuracy 


■2.5+aoos-  >| 

'StdThrd 

•"Drill 


10  M 

T<  -  r-06%0.85^  fO.lt 


|< S.2!0.0f~ 

k S.2S"t0.0Z° 


5 .jj  Thndsper  Qtuf, 


..J     ""  hole 

MACH.  STEEL 

Finish  ft  0.01  "Case 

Harden     .^^ 


Stamp  Name  of  Shrapnel,  Partfipemtioh, 
Dimensions  paged.  Place  of  Manufacture, 
"tea,  ' 


V>Q08"Max. 


to 


and  Date  (war) 
\* 


om^ 


T 

,-''0.25° Ream 

O.I2S"X0.6ZS" 

"'Steel  Rn  Drive 


0.125' 


O  Pin 

)fr  TOOL  STEEL 
tti  IQseHarden) 
002"       -*jfl3£ 
Flnish/tQOf^ . 


SAW STEEL  (Harden)-^  U-0.06"Min. 
Finish/ 1 0.Ol".  Finish  gaging Surfaces/g 
Stamp  Name  of  Shrapnel,  Part,  Operation, 
Dimensions  gaged.  Place  of  Manufacture 

x  and  Date  (year)  fig.82  «. f.'.. 

§p/2-"->j  §  Va—zm'Max. 


SAW  STEFL 

(Harden) 

Finish  gaging  Surfaces  fa 

FIG.  77 


0.125  R. 


OPERATION 

r&JjL 

hr^i 

So3£ 

Finished 

2  751535' 

0.101  Drill 


<0I25" 


Body 

MACH.STEEL 
(CaseHarden) 
Fmish/iO.Or 


HEAD 

A 

B 

r. 

D 

?9b  -inch  Shrapnel 

4" 

1" 

Of,': 

„,,' 

3  * 

4' 

/" 

tno- 

'.:■"," 

3.8    " 

4.5- 

123 

ui" 

;::. 

4.7    » 

V 

/."■;' 

w 

?  & 

6    " 

b" 

'75' 

?f..- 

<:>:-' 

Head 


u  \*~i"-> 


of> 


«     s  »^      si? 


FIG.  80 


MACH.  STEEL(Case  Harden) 
Finish  i  ±  Q0r0neA-l.  16" Ma, 


vsh/±0.0l"0neA-l.  76"'Max 
0ne-k-l:75"Min 
FI6.8I 


HI6H- SPEED STEFL 
%     *&»     finish fiQO/" Han/en 

§     \>j  V0.05tM02"  f~~Q85"-~: 


« 


H* 


J9— -H   [ 

SAWSTEEL(Harden) 
Finishj.±0.0ln 
FI6.83 
OPERATION  1 


Ui/e'  >J  MACH.STEEL  (CaseHarden) 
Finish JtO.Ol" 
FI6.78 

-3,5'- 


-A 


U.'--2.844"M,h J&5&U- 

SAW  STEEL  (Harden) 
Finish/ ±0.01" 
FIS.  84 


^Max. 


0.125" 


% 


a         I  cs 


SAW  STEEL(Harden) 
Finish  J. 't  0.0/" Finish  gaging  Surf aces/g 
FI6.79 


needed,  the  rate  of  production  is  here  comparatively  low. 
After  the  machined  head  is  severed  from  the  bar,  it  is 
placed  in  a  special  chuck,  Fig.  86,  on  a  turret  lathe,  and 
the  mouth  is  countersunk  with  a  beveling  tool  carried  in 
the  turret,  as  shown  in  Fig.  60.  The  thread  for  holding 
the  head  to   the  case  is   chased  on  in   a  turret  lathe. 


FIG.98 
OPERATION  6 


FI0.99 
OPERATION  7 


MIDVALE  EXTRA  HI6HSPEED  STEEL 
Harden  and  Grind  *Q.0l' 

FIG.92 


FIG.  100 


--Z.Z5±0.05- 
Z.I25"—->\ 


05Drill 
i  0375" Deep 


1-1 

VoA 


OPERATION  8  ^P-"^^*.**™* 

1    •••    u05-sl  per Inch,  US. 
I  Standard 


8-Threads per  Inch, 


T 


FORGED  STEEL 
Finish  J  ±0.01* 
FIG.  101 


[HI 


The  washer  is  made  of  thin  sheet  metal  and  is  placed 
in  the  head,  and  the  edges  are  crimped  down  into  the 
grooves  of  the  head  with  a  double  roller  tool,  as  shown  in 
Fig.  60,  details  of  the  tool  being  given  in  Fig.  96. 

After  the  head  has  been  thoroughly  washed  in  hot  soda 
water,  the  inside  is  painted  by  hand ;  then  the  short  piece 
of  tube,  or  retainer,  is  put  in  place  and  melted  resin  is 
poured  in,  as  shown  in  Fig.  62.  The  resin  is  allowed  to 
cool,  and  then  the  head  is  placed  in  a  special  screw  chuck 
and  the  resin  faced  off,  as  shown  in  Fig.  63,  details  of 
the  chuck  being  given  in  Fig.  101.  The  tool  used  is  a 
standard  left-hand  facing  tool. 

The  purpose  of  milling  notches  in  the  head  is  to  provide 
means  for  locking  the  fuse  securely  after  it  is  screwed  into 
the  mouth  of  the  case,  metal  on  the  fuse  being  forced 
into  these  notches  with  a  punch  and  hammer.  The 
notch  milling  is  illustrated  in  Fig.  64,  the  fixture  being 
a  rather  simple  one,  but  answering  the  purpose  perfectly. 


Head  (Bar  Stock) 

operation  1.    machine  without  thread  and 

countersink 

Transformation — Pig-.  65.  Machine  Used — Gridley  or  Cleve- 
land automatic,  Pig.  59.  Number  of  Machines  per  Operator — 
Three.  Work-Holding  Devices — Split  chuck.  Tool-Holding 
Devices — Circular  form-tool  holder,  cutoff-tool  holder,  drill 
holder,  rough-tool  holder,  combination  groove-tool  and  reamer 
holder,  tap  holder  and  adapter.  Cutting  Tools — Circular  form 
tool,  Fig.  66;  cutoff  tool,  Pig.  67;  twist  drill,  Fig.  68;  roughing 
tool,  Fig.  69;  set  (2)  grooving  tools,  Fig.  70;  facing  tool,  Fig. 
71;  combination  counterbore  and  reamer,  Fig.  72;  tap,  Fig.  73 
Cut  Data — 50  ft.  surface  speed.  Coolant — Zurn  oil.  Special 
Fixtures — Stop,  Fig.  74.  Gages — Maximum  thread,  plug.  Fig. 
75;  minimum  thread,  plug,  Fig.  76;  diameter  and  length  of 
thread  (operation  1),  Fig.  77;  length  over  all,  Pig.  78;  length 
of  shoulder  (operation  1),  Fig.  79;  depth  of  groove,  Fig.  80; 
maximum  and  minimum  inner  diameter  of  crimp  wall,  Fig.  81; 
outer  diameter  and  depth  of  crimp  wall,  Fig.  82;  diameter  of 
small  end,  Fig.  83;  diameter  of  large  end,  Fig.  84.  Production 
— 115  per  8  hr. 

OPERATION  2.     COUNTERSINK 

Transformation — Fig.  85.  Machine  Used — Brown  &  Sharpe 
turret  lathe,  Pig.  60.  Number  of  Operators  per  Machine — One. 
Work-Holding  Devices — -Special  chuck,  Fig.  86.  Tool-Holding 
Devices — Tool  holder.  Fig.  87.  Cutting  Tools — Beveling  tool, 
Fig.  88.  Cut  Data — 210  r.p.m.  Gages — Diameter  of  fuse-seat 
bevel,  Fig.  89;  minimum  diameter  of  fuse  seat  and  fuse-seat 
thread,  Fig.  76.     Production — 800  per  8  hr. 


0.75 

Q3I?(ifTap.Sfd 
0.6" 


"WOO, 
0.00?-. 


FIG.  85 


™?7£)W«-"ov  P0RGED  STEEL 

,..0.312  (^0.625  Std.  FinishftQOl" 

'    ^.fil/sterneaa Screw 

*\d9V-i  F*k  -/5-'>|03£  ■  2.125"  >\ 
~J4Jh,ds.perhch,U,S.Stcl,L.H,  [^~\>-04n 


Finish/ 1 0.01  and  Harden 
Bushing 


Assembled  View  for 
3-inch  Shrapnel  Heads 

„  Three  for  each  Nut 

Finish  fiO.002" 

MACHINE  STEEL 
'Case  Harden 
Wrench  Socket 


^40" 


Finishf'3.01 
Harden 


-Q002-- 


12  Wds.  per  inch, 
US.Std. 


-h(26k- 


9A0Z5  Drill 

0.6Z5"Tap,Std. 
[<l./">«/.0'*-*l0.8}< 3.6"- >| 

r* : 6.95" >] 

Body  for  Lathe  27-LT-l 

m"*o.oo(f-Qoo? 


I  ^fc  V       MACHINE  STEEL 

|?lPj3     Finish  ft  0.01" 

^§  Case  Harden 


COLD-DRAW  STEEL  Finish f*0.0l 

Lacking  Nut  for  3-inch  Shrapnel  Heads 


-0.75  Ream  ^-f.J^-x 

4  Threads  per  Inch,  US  5tH.  Left  Hand 
FinishfiQOl" 
Locking  Nut 
"winch  *W5Ul&<  165**  l^h'ds.         lefiHand,F/^J5&ril:         For  G34g)/yiisierhead Stf  Sere* 
■  ."-iW  -^0.15"  l-perlnch      A      ^.^.™™Q/i-/'       H        ,  ^H.ih^ 


OSIzUfTap,.  *«3«- 

SM0.6" 
,,-x  •xDeep , 
&**  -^ 

j  IS 

iw->0.002-- 


K -!*-—*! 

$     Chuckscrew  for'  3-inch.  Heads 

"aw"(i)k6l5"FilisttrhtodSleel.&r*w. . 

i     v 

\lZTHds.---'  50°-'  y''--40°  0.25 

7 per -Inch',  U5.Std'-'U/j">^/.o">\ 


•$.0.75' 'Ream       \*,l6&'li*t625S\    M>D"6TWds.perhttSS. Hot -Lathe  14-17-3      FORGED  STEEL    \  '"    0.45-A    \^}*al5"  fe& 
(*--'-  325*~»H    A-ZS,g  -    .•••••    -Engine Lathes        Finish f  ±0.01"    \  «.*'?:$%>  ~ 


perlnch 


ktrsslfb" 


02- 


U.S.  Standard  Threads 

Finish fiOOl" Case  Harden 

MACHINE  STEEL 

Chuckscrew 


Finish ftO.01,  Harden 
MACHINE  STEEL :  FinrshftO.Ol"Case-Harden  J00L  57K1 

Chuckscrjewvfoc.Base-Pluga'  s+°fc 

i-0*U  F1G-86 

yo.4"*pz&- 


s_ 

2,0.177'' 0.5"Filisterhead 
Steel  Screws 


lr        \<0.6  ->)  Stamp  Name  of  Shrapnel,  Part,  Dimension  gaqed, 
Finish  ft  0.01,  Case  Harden  Race  of  Manufacture,  and  Date  (Year) 

FIG.  89 


OPERATION  2 


HIGH-SPEED  STEEL 
Finish  ftO.01" Harden 
Chamfering  Tool 


FI6.88 


Finish ftO.01" Harden 
Beveling  Tool 


[12] 


FIG.  94 


.---'""n 


1-0.000" 


Assembled    Views 


->f?53K 


Oil  Drill 


0.5"rapStdLtf 


TOOL  STEEL 

(flarden) 
Roller 


nnishftOOl" 


U 


H5*!  Standard  Thread 


^"^-hO.003 
TOOL  STEEL 

(Harden) 
Roller    Pin 


FIG    96 

OPERATION  4 


■3.775  -- 

("Case  harden) 
Body 


.■O.I?SxO.S"steel  fin-Daw; 

A 


Stamp:  narmor" 
„       shmpnel,  part, 
ft    '*-'/-^    Mqaqedimensions 

— -V ^jp^flbcpar 

n_^ manufacture. 


%' 


\anddate,(yedri 


YawW 


TOOL  STEEL 
nnish/t0.0l"t1arden 
FIG.  97 


OPERATION  3.  TURN  THREAD 
Transformation — Fig.  90.  Machine  Used — Brown  &  Sharpe 
turret  lathe.  Number  of  Operators  per  Machine — One.  Work- 
Holding-  Devices — Special  chuck,  Pig-.  86.  Tool-Holding-  De- 
vices— Chamfering-tool  holder,  holder  for  circular  thread 
cutter.  Cutting  Tools — Forming  tool,  Fig.  91;  chamfering 
tool,  Fig.  88;  circular  thread  cutter,  Fig.  92.  Cut  Data — 200 
ft.  surface  speed.  Coolant — Dard  oil,  put  on  with  brush. 
Gages — Maximum  thread,  ring,  Fig.  93;  minimum  thread,  ring, 
Fig.  93;  diameter  length  of  finished  thread,  Fig.  77;  maximum 


and  minimum  length  ot  shoulder,  Fig.  79.  Production — 250  per 
8  hr.  Note — This  is  a  thread-chasing  operation,  as  can  be 
seen  from  the  illustration. 

OPERATION  9.  MILL,  NOTCHES 
Transformation — Fig.  102.  Machine  Used — Brown  &  Sharpe 
miller,  Fig.  64.  Number  of  Operators  per  Machine — One.  Tool- 
Holding  Devices — Arbor,  Fig.  103.  Cutting  Tools — Milling 
cutter.  Cut  Data — Cutter  runs  370  r.p.m.  Special  Fixtures — - 
Fig.  104.     Production — 1400  per  8  hr. 


f-0.25" 


0875"+0.000„; 

u°fi>  -Q002-.  ■ 


025"-: 


For  0.125*0.25*0.45  long,  Steel  Key 

v<Q37r  60i J  ... 

15.25'-'-- - - 


TOOL  STEEL 


Arbor 


Fin!shftO.OI 


Stamp  Name  of  Machine,  Ptace  of 
Manufacture  and '  Date  (Year) 


One  A -7.5' 
FourA=0.75" 


J   j<-/J75->f 


Fl£.  102 


Finishj"±0.0/  Case  Harden 
MACHINE  STEEL 

Bushing 

Fie.  103 


Finish  J 'i  0.01  Case  Harden 
MACHINE  STEEL 


Nut 

COLD-DRAWN  STEEL 

FimshfiO.Ol" 

1, 0575*0.75'r5teel  Pin-Drive 


14  Th'ds.per 
inch.USSfd, 


MACHINE  STEEL 
Finishfi0.0l" 

Spindle 


ostew  0.312"® 'jlh^f  I* 

— 0.Ae  ? 
0.315" Ream-'     0375R.         [=3     0" 


TOOL  STEEL  , 

FinishpO.05 

Harden 


Stop 


0.051 


J,O.I9"*C75"Sty.  Pivot  Point 
Headless  Steel [ 
Screw 
Base 


STEEL  MUSIC 
WIRE 

Free 
Height. 
.„  6  Coils 

Finishjt0.05 
Spring 
„,»    Finish  f 


\<~2.0~"">\    '~Q3l2"(g)TapSta'.Q375nDeep 

~Fi ' — 

''■Table  of  Milling  Machine 


FI6. 104 
OPERATION  9 


6,0.3l2W*!0"Std.Filisterhead Steel 'Screws 

BRONZE       Finishft0.0l" 

Gib 


•     L-1    , 
0.375"  4.4 

COLDDRAWN  STEEL 
Pivot  Stud 


[13] 


OPERATION  4.     CRIMP  IN  WASHER 

Transformation — Fig.  94.  Machine  Used — Drilling  machine, 
Fig.  61.  Number  of  Operators  per  Machine — One.  Work- 
Holding  Devices — Special  chuck.  Tool-Holding  Devices — 
Crimping-tool  holder.  Tools — Crimping  tool,  Fig.  96.  Cut 
Data — 260  r.p.m.  Gages — Depth  of  disk,  Fig.  97.  Production^ 
1400  per  8  hr. 

OPERATION  5.     WASH  IN  HOT  SODA  WATER 

Number  of  Operators — One.  Description  of  Operation — 
Operator  puts  40  heads  into  a  dipping  basket  and  sets  it  in 
cleaning  solution;  when  grease  is  off,  the  heads  are  rinsed 
in  hot  water;  if  not  too  greasy,  about  2  min.  is  enough  time 
for  cleaning.  Apparatus  and  Equipment  Used — One  tank  of 
boiling  Wyandotte  metal-cleaner  solution;  one  tank  of  boiling 
water;  metal  dipping  baskets.  Production — 2500  per  day. 
OPERATION  6.     PAINT  INSIDE 

Transformation — Fig.      98.        Number     of     Operators — One. 
Apparatus  and  Equipment  Used — Brush  and  pot  of  asphaltum 
varnish.     Production — 1200  per  day. 
OPERATION  7.    INSERT  RETAINER  AND  FILL  WITH  RESIN 

Transformation — Fig.  99.  Description  of  Operation — Oper- 
ator placesi  head,  small  end  down,  on  plate,  then  puts  in 
retainer  and  pours  in  melted  resin,  Fig.  62.  Apparatus  and 
Equipment  Used — Metal  plate,  furnace  and  kettle,  pouring 
ladle.     Production — 1200  per  8  hr. 

OPERATION  8.  FACE  OFF  RESIN 
Transformation — Fig.  100.  Machine  Used. — Small  lathe,  Fig. 
63.  Number  of  Operators  per  Machine — One.  Work-Holding 
Devices — Special  screw  chuck,  Fig.  101.  Cutting  Tools — Left- 
hand  facing  tool.  Cut  Data — 220  r.p.m.  Production — 1200  per 
8  hr. 


Diapheagm  (Forging) 


OPERATION  1.     DRILL  AND  COUNTERBORE 
Transformation — Fig.     106.       Machine    Used — Turret    lathe. 
Number  of  Operators  per  Machine — One.     Work-Holding  De- 
vices— Special  screw  chuck,  Fig.  107.    Tool-Holding  Devices — 


Drill  holder  and  bushing,  countersink  holder  and  bushing, 
counterbore  holder  and  bushing.  Cutting  Tools — Twist  drill; 
countersink,  Fig.  108;  counterbore,  Fig.  109.  Gages — Maxi- 
mum diameter,  ring,  Fig.  110:  minimum  diameter,  ring,  Fig. 
Ill;  maximum  and  minimum  diameter  counterbore,  plug,  Fig. 
112;  depth  of  counterbore,  Fig.  113.  Production — 400  per  8  hr. 
Note — These  are  forgings,  trimmed  outside  in  a  die,  and  only 
have  to  be  drilled  and  counterbored. 

OPERATION  2.  HEAT-TREATMENT 
Number  of  Operators — One.  Description  of  Operation — 
Diaphragms  are  kept  in  furnace  until  temperature  reaches 
1600  deg.  F.,  then  taken  out  and  placed  in  cottonseed-oil  bath 
to  harden;  next,  are  rumbled  in  hot  soda  water  to  remove 
scale,  and  are  then  drawn  to  900  deg.  F.  in  saltpeter  bath. 
Apparatus  and  Equipment  Used — Furnace;  perforated  copper 
basket,  24  in.  long,  15  in.  wide,  12  in.  deep;  rumbling  device. 
Production — 4800  per  8  hr. 

OPERATION  3.     REMOVE  SCALE  FROM  COUNTERBORE 
Machine  Used — Drilling  machine.      Tool-Holding  Devices — 
Drill  chuck.     Cutting  Tools — Twist  drill,  ground  to  suit.     Pro- 
duction— 1400  per  8  hr. 

OPERATION  4.  GRIND  BASE 
Transformation — Fig.  114.  Machine  Used — Diamond-disk 
grinder,  Fig.  115.  Number  of  Operators  per  Machine — One. 
Note — Operator  holds  piece  on  disk  until  a  flat  seat  is  ground 
on  the  bottom;  one  operator  generally  grinds,  paints  and 
assembles  with  a  total  of  from  800  to  1000  per  day. 

OPERATION  5.     PAINT  BASE 
Transformation — Fig.      116.     ■  Description     of     Operation — 
Operator    applies    asphaltum    varnish    to    base    with    a    brush. 
Production — See  grinding  note. 

OPERATION  6.     ASSEMBLE  TUBE 
Transformation — Fig.  117.    Description  of  Operation — Oper- 
ator   presses    tube    into    diaphragm,    as    shown    in    Fig.     118. 
\oparatus  and   Equipment   Used — Fixture,   Fig.    119.      Gages — 
Length,  Figs.  120  and  121.     Production — See  grinding  note. 


0.6- ->n ■aoi" 


K-0<5-->j 
0.t5"->\    fO.45^ 

cor- 


6ive  bottom  of  diaphragm  a 
tieayy  coat  of  non-acid  paint 


Great  care  should 
be  taken  to  remove 
all  burrs,  sharp 
corners  and  scale 

Diaphragm 
rORGED  steel 
±0.005" 
FIG. 105 


ao5><Y<±aoo2Zt 

0.05'^-tSMZT 


>J  Vo.24^ :-  IS"  -*U 1.25"-—  J 

MIDVALE  EXTRA  HIGHSPEED  STEEL 

Harden  &  Grind 
±0.01' 
r„        FIG.  108 

----- >, 


FIG.  106 


„  <~l.?5"y^ 

0.5l2"(f6)  TapStil-^\<-  0. 22  " 
~K — 


Stamp:  name  of  shrapnel,  part, 
FIG.  109        operation,  place  of  manufacture 
and  date  (year) 


■A04^- 


$%% '^fyw'SttSteeimsterhead Screws.  FJatMnt 

O-Uld  J(  U.O/O  „      n         p  v  Round    » 

rm*£t&"*"-      "      -■'■$?. ...»    Harden 
3-OI5"x 


0.2S"TapSfd. 
■0.152" Drill 
4.875-"-- 

-0.25% 'head 
Std.  Screw 


Stamp:  name  of  shrapnel,  part, 
name  and  size  of  lathe 


FIG.  110 

Stamp-  name  of  shrapnel,  part, 
operation  dimension  gaged,  place 
of  manufacture,  and  date  (year) 


I- Steel  Key 


ft/'frass  Loc*mstPOlntW'n3ea ' Screm  Used'on  ^ner  &  Swasey  Hand  Turret Lathe 


MACH.    STEEL 

Body 
FIG.  107 

-2.S" 


02l6"filisterhead 
..STandand  Screw 

>i  rt0.25"fieam 


hf 


H375U  U 

QI2S"Stti.Tap  \ 


OPERATION      I 


ALL  MATERIAL  TOOL  STEEL  EXCEPT 
WHERE  OTHERWISE  NOTED 
O  FINISH /±0.0l"hARDEN 

■A  V-0.23" 


FIG.  Ill 


Assembled    Views 


FIG.  113 


t<—  -2.875-A 
Arm 

MACH.  STEEL 

3-0.216  xOTS'Std.  fHisterheaa 'Screws 

l-O.I25'xa28'  "  headless  Pivot  Point 

Steel  Set  Screw 


§!£(  003"^ 
""  Pin 


K 2.575 

■"  ooti 


Stamp:  name  (fshmpne' 
parfgagr 


SIZE 

A 

B      1 

.  '.* " 

03lr 

s. 

DM" 

3.6" 

01," 

049?" 

4  7" 

Of 

0.498" 

i» 

0.5" 

0498' 

[14] 


Locking  Pins 
operation  1.    machine  (bar  stock) 

Transformation — Fig.  122.  Machine  Used — Brown  &  Sharpe 
automatic.  Number  of  Machines  per  Operator — Three.  Cut- 
ting Tools — Cutoff  and  form  tool,  Fig.  123.  Coolant — Zurn  oil. 
Gages — Length,  Fig.  124.     Production — 2500  per  8  hr. 

Work  on  the  Diaphragm 

Since  a  diaphragm  is  forged  and  then  trimmed  in  a 
die,  the  amount  of  machining  work  needed  is  small.  It 
is  held  in  a  special  chuck,  Fig.  107,  in  a  turret  lathe  and 


drilled  and  counterbored.  Following  the  heat-treatment, 
which  is  given  in  detail  under  the  proper  heading,  the 
base  is  ground  on  a  disk  grinder  in  order  that  it  may 
seat  properly  in  the  case.  Removing  scale  from  the 
counterbore  is  simply  a  scraping  operation,  and  an  old 
twist  drill,  ground  to  suit,  is  used  in  a  drilling  machine. 
The  base  is  next  painted,  and  the  center  tube  is  pressed 
in  with  the  special  fixture,  Fig.  119.  The  work  on  locking 
pins,  central  tubes,  inner  tubes  and  retainers  is  all  simple. 


A 

^ 

40& 

*• 
Ki 

T 

1          I    ^ 

1      1 

Stamp  :name  of  machine,  kind  of 
steer,  place  of  manufacture  and 
date  (year) 

\^0.05n 


S./ 

Stamp:  name  of  shrapnel, 
part,  dimensions  gaqed 
place  ofmanufacture  and 
date(year) 


FIG.  114  FIG. 115 

OPERATION    A 


FIG.II6,0P.5 


Drive  andpeen  after 
assembling  head  to  case 

.STEEL 

f/nish/tO.OOS 

Locking  Pin 

FIG.  122 


<Zt»>± 


#—l.5—->\ 


T^fiOj'iTri/l 


0.375"Tap 

16  US  Std.Thrd.perin 
HIGH  SPEED  STEEL 
finish /t 0005" 

FIG.  123 


W(iB^'-' 


aizs>\ 


s.    U 


MACH.  STEEL 
finish /±QOI"CaseHarden 
FJG.I24 


•^1<--ZJ75-->1  Vk 
^  Centering     : 
y   **      Pin 


06Z5%pStd. 

Counterweight     finishf+tWl" 
COLD  DRAWN  STEEL    062SxtS"Sfd. 

Pinion    Shaft         & 

C0LLf^f^nSnv"L    0.625xO.TS"Std Steel Setscrm 
finish /tOOOl       m(m2»„     »Q,tterPin 
*I.I2S"«    » Washer 


Ram 
COLD  DRAWN 

.  STEEL 
finish f +0.0/" 
0.376 xl"Sfti.0c?c"^ 
Steel Setscren"^     ^ffi'Recm 


Assembled     View 


Adjustable  Block 
MACH  STEEL 

finish  ft 00l"Case  Harden 
0.437Yp  •kl'Std.SteelSetScrevr' 


Test    Piece 

COLD  DHAWN  STEEL 

finish  ft  O.Ol'Case  Harden 

A  -  6.355"for3"Gammon Shrapnel 


FIG.  121 
OPERATION  6 


8" 
Plate 
MACH.  STEEL 
rini$hft<Wl' 


[15] 


■594*001- 


.O.IR. 


=*f- 


"dO'^OM" 

—fee 


■042^0.05"  °05'  0.375*0.002" 

SEAMLESS  DRAWN  BRASS  TUBIN6 


One  A-60   B'0.625 


TOOLSTEEk 
Finish ftOOl" Harden 

0/ 


■1.18- 


x 


# 


FIS.12.5 

-—  >^-0.52^ 


^H^_I K^^ 


> 


0.15  R 


L 


■-I.5- 


COLD -DRAWN  STEEL 
Finishf*0.0l"  Case  Harden 
FIG.  \zr 


HIGH-SPEED  STEEL 


Finish  J 't  0005 
Harden 
Finish  Cuffing 
Fdgefg 


Finish ftO.Ol"  Finish  Caging 

Harden  Surfaces  Jg       ' '   t 

k s.93  Min.— -H  0.125 

FIG.  129 


X*  Stamp  Name  of  Shrapnel,  Parf,  Dimension  gaged. 
Place  of  Manufacture  and  DatefYear) 


f0.425>\ 


0.125 ■■■ 


s  0.125  R. 


■2.0- 


~T 


FIG.  128 


O.ZI2"(0.V:M 


OPERATION  1 


MACHINE  STEEL 
Finish  ftO.Ol"  Case  Harden 
FIG.  130 


Tube   (Inner) 
operation  1.    machine 

Transformation — Fig.  131.  Machine  Used — Brown  &  Sharpe 
automatic.  Number  of  Machines  per  Operator — Three.  Tool- 
Holding'  Devices — Four  tool  holders.  Cutting-  Tools — Two 
countersinks,  Fig.  126;  two  belling  tools,  Fig.  132;  chamfering 
tool.  Fig.  133;  cutoff  tool,  Fig.  134.  Cut  Data — 2400  r.p.m. 
Coolant — Lard  oil.  Gages — Overall  length,  Fig.  135;  maximum 
and  minimum  diameter  of  bell,  Fig.  135.  Production — 4200  per 
8  hr.     Note — Seamless  copper  tubing  is  used. 


Tube  (Central) 


OPERATION  1.  MACHINE 
Transformation — Fig.  125.  Machine  Used — Brown  &  Sharpe 
automatic.  Number  of  Machines  per  Operator — Three.  Tool- 
Holding  Devices — Four  tool  holders.  Cutting  Tools — Two 
countersinks,  Fig.  126;  two  belling  tools,  Fig.  127;  cutoff  tool, 
chamfering  tool,  Fig.  128.  Cut  Data — 2400  r.p.m.  Coolant — 
Lard  oil.  Gages — Overall  length,  Fig.  129;  maximum  and 
minimum  diameter  of  bell,  Fig.  130.  Production — 2500  per 
8  hr.     Note — Seamless  brass  tubing  is  used. 


Sfamp  Name  of  Shrapnel.  Parf,  Size,  Place  of  Manufacfure  and  Da  fe  (Year) 

.<-i0.233°:™£ 


Stamp  Place  of  Manufacfure  and  Dafe  (Year) 


\0.I8^<<102 

14*0.002" 

005 
R- 


0.002 


■m- 


Force  into  Tube 
Inner  Tube 


0Q2> 

id 


FIG.  I 


iS 


07\^'Dull 
I  Corner 

COLD -DRAWN  STEEL 

Finish  J  ±0.01,  Case  Harden 

FIG.  132 


Stamp  Name  of  Machine,  kind  of  Steel,  Place  of 
t<0.25*  Manufacture  and  Date  (Year) 


~T 


FIG.  133 

Stamp  Name  of  Shrapnel,  Part,  Dimensions  gaged, 
Place  of  Manufacture  and  Date  (Year) 


?0.I8< 
ft 


HIGH- 
SPEED 
STEEL 


M 


■^A.FinishpO^,^ 


MACHINE  STEEL 


FIG.  134 


Finish  f*00i  Case  Harden 
FIG.  135 


[16] 


K-//Z5'- 


Retainer 


Seamless  Drawn  Brass  Tubinq 
0.058"  Tnick  ±0.01" 

FIG  136 


Stamp- name  of  machine,  kind 
of  sreel,  place  of  manufacture       „ 
and  date  {year) 

high-speed  steel  (Harden) 
Finish fg±  0.01" 

FIG.  137 
OPERATION  I 


i  IT 


l2U.S.StdIhrU. 
per  in. 


\j/ 


HIGH-SPEED  STEEL  (Harden)  l^J™Wn£%W%CL 
finish  fa -t-OOn"r\c  iu  operation,  place  of manurac- 
nnisnjfg.  u.wa  nG.138  /^  ^  ^^  ^^ 


UK 


J'     ■&    ** 

T 

A 

'W7"DriH 

?* 

,  .0.125"/?. 

.> 

Y 

<-O.I25n 


MACH.  STEEL  (Case  Harden)  Stamp; pome pt shrapnel, 

Finish  s-t-n  ni"  part,  dimensions  qaqed, 

finish  /T  0.  Ol  rjace  ofmanufn&jk  ind 

FIG.  139  date  (year) 


Eetainek 
operation  1.    machine 

Transformation — Fig.  136.  Machine  Used — Brown  &  Sharpe 
automatic.  Number  of  Machines  per  Operator — Three.  Cut- 
ting Tools — Cutoff  tool,  Fig.  137;  chamfering  tool,  Fig.  138. 
Gages — Length,  Fig.  139.  Production — 2500  per  8  hr.  Note — 
Brass  tubing  used. 


Washer 
operation  1.    punch  (sheet  steel) 

Transformation — Fig.  140.  Machine  Used — Crank  press. 
Number  of  Operators  per  Machine — One.  Punches  and  Punch 
Holders — Punch,  Fig.  141.  Dies  and  Die  Holders — Die,  Fig.  142. 
Lubricant — Machine  oil.  Production — 8000  per  8  hr.  Note — 
This  completes  the  washer. 


cr? 


.rm 


1    WkW 

For  2.95  &  3"Com.ShrapnelA*0.28 
For58"4.7"&6"Com.ShrapnelA-039' 
£5Lh,  Washer 


0 


Assembled  Views 


iff 

K 4.25" >| 


Die  kC7 

STEELl 'Harden)  <|_ 


0/R,    Ml"R. 
— VA^  ±  , 


jtf-i 


T00LSTEEU?J    '      A+ffi, 

Form"29  i^<nishJ±0M"\,n      W0? 
Punch  «&& —| — 1\^ 

STEEL     &b 


mm 


Finish{±0.005"  ■     ,         -      „^„  garden'  ,          Finish  f±0.005JT 
OJOlWSteelPin.      f  S99M+0S3  A  fQ2S%075?\        v         '    K.Q^?H      .J^,  ^ 
-.•2.I7-  .  «. 2.115"— —A  'Harden 


Drive  and  Bend      \*- 
iW'^J001"'",'^  n*i0*     For295 &3  Co/n.Shrapnel  A*Q/8'.B=0.53"  .  Piercing  Punch 

wV^klM"rt       \!  For3.8A7&6"Com.Shrapnelr\-0.29,3-0.64"For2.95"&3"Com3raPnelA-0.22" 

J^mPm&^W^fl       |f   ...  For38:4.r&6"Com Shrapnel ^0312 

M    mwM  I  n*rrrv  K.....^ u     F.G..4I  ^-p* 


■J-- 

\*-l.85"-^l.85"A 
7"—  --,-— ----- *f 


„    \<---ZII5' 
For2.95"&3"Com.Shrapnelk~0.22",     U-275HaJj»   \*~  1.125"  A«-0.99& 
B=0.375"C=0.33.For3.8''4.7"&6"     „  ~um  -Htf# 

Com.ShrapnelA'0.3l2"(§,B-0.437U)tC-044"^  %r  sp% 


QX^TapSfd,  ->}l.687y-tt 


,    m 4- *t 


(»&* 


.  0.375'TapStd. 
\  / 0.75" Deep 


TfTrf 


K=l 


tr1 

c„  CAST  IRON  ±0.01"  !    O7r-0.000, 

£,  0.3l2"(jl)xl.25"Standard  Square  Head  Steel  Sefscrews*'*®  +0.005" 
Die  Holder 

"iSfc  FIG.  142 

T       OPERATION  I 


URearriM 


ft 


rReam) 


& 


W-25- 


Harden-  -  ■  ■         TQ0L  STEEL>Flnishj 
:0.37S"Drill     Blanki"9  Pu™h 


±0.005 


%   0.375'TapSfd. 
-\-Z15"-A/ 


? 


,0.375Drill 


<5— 


K-/->H- ; 


h  *as 


SHEET  STEEL±0.0I" 
Guide 


flf$  ■>JSv^ttt^%teK1 


(< -5£5- — H     , 

ftW<5£»  STEEEFinishji±Q005 
3, 0.375\0875"Stb.  Sq.  Head  Setscnws 
Punch  Holder 


0.375"DrillA    K  "U 

MACHINESTEEL 
FinishJ. ■±0.005" 
Guide  Support 


SHEET  STEEL  ±0.01" 
Q375"XI.25*Tap Bolts 
Stripper 


[17] 


FIGS.    144    TO   149.      VARIOUS   BULLET-MAKING   AND  POWDER-LOADING    OPERATIONS 

Fig.    144— Casting    ingots.      Fig.    145— Extruding    the    wire.      Fig.   146— Special  ball-forming  machine.     Fig.  147— Press  and 
wire    reels.      Fig.    148 — Roll    feed    and    tumbler.      Fig.    149 — Powder-loading  machines. 


H8] 


The  lead  balls  used  in  shrapnel  are  both  round  and 
six-sided,  as  shown  in  Fig.  152,  and  are  made  in  prac- 
tically  the    same   way,    only    different    dies   being   used. 


DIMENSIONS 

SI 
SIZE 

1RAPNEL 
DRAWING     NO. 

PIECE 
MARK 

\((y^&  Faces 

Is \ 

0.46"Flats 

2.95" 

75-2-4/- 

41 F 

3" 

75-2  -4 

4F 

3" 

75-2-137 

137  F 

3' 

75  -2  -151 

151 6 

3" 

75-2  -152 

75  H 

Q 

0.54"t0.005" 

3.8" 

75-2-145 

I45BI 

4.7" 

75-2-/47 

147  A 

5" 

FA.  3574 

G 

0'6"id.005" 
COMPOSITION  OF BALLS ' ■§5$%%}ny 

6" 

75-4-12 

12  CI 

6" 

75-7-37 

37CI 

7* 

FA.  3578 

Making  Balls 
operation  1.    casting  ingots 

Transformation — Fig.  143.  Number  of  Operators — One 
Description  of  Operation— Operator  pours  melted  mixture  of 
7  parts  lead  and  1  part  antimony  into  mold  and  allows  it  to 
cool  for  3  or  4  min.,  then  inverts  mold  and  allows  ingot  to 
drop  out,  the  shrinkage  being  sufficient  for  ample  clearance. 
Apparatus  and  Equipment  Used — Rockwell  melting  furnace, 
ladles,  tongs  and  water-cooled  mold,  Fig.  144.  Production — 
43  per  day  per  mold. 


OPERATION  2.  EXTRUDING  THE  WIRE 

Transformation — Fig.  150.  Machine  Used — "Waterbury- 
Farrel  700-ton  hydraulic  press,  Fig.  145.  Number  of  Machines 
per  Operator — One.  Dies  and  Die  Holders — Fig.  151.  Pressure 
Required — About  650  tons  total.  Production — 75  per  day. 
Note — A  spool  of  wire  usually  consists  of  five  extruded  ingots, 
or  about  500  lb. 


OPERATION    3.      FORMING   BALLS   ON   SPECIAL   MACHINE 

Transformation — Fig.  153.  Machine  Used — Special  Water- 
bury-Farrel  machine,  Figs.  146  and  154.  Number  of  Machines 
per  Operator — Four.  Tools — Shearing  ring  punch,  Fig.  155; 
forming  punch  and  die,  Fig.  156;  shearing  punch  and  die,  Fig. 
157;  transfer  plate,  Fig.  158.  Cut  Data — 68  strokes  per  minute. 
Production — 30,000  per  day.  Note — 500  lb.  of  wire  makes  about 
380  lb.  of  balls;  the  balls  for  3-in.  shells  run  41  to  the  pound; 
for  4.7-in.  shells,  32  to  the  pound;  and  for  6-in.,  22.90  to  the 
pound. 


OPERATION   3-A. 


FIG.   152.     BALL  DIMENSIONS 


FORMING   BALLS   ON   A   PUNCH   PRESS 
AND   RUMBLING 

Transformation — Fig.  159.  Machine  Used — Waterbury- 
Farrel  crank  press,  Figs.  147  and  148.  Number  of  Operators 
per  Machine — Two.  Punches  and  Dies — Fig.  160.  Production 
— 200,000  per  day.  Note — 500  to  600  lb.  of  balls  are  rumbled 
at  a  turn  to  remove  fins  left  by  dies;  this  operation  takes 
about  15  min.;  press  runs  80  strokes  per  minute  and  takes  12 
wires  at  once. 


-o.izs' 


\z-U3"'->i«-—-l.48""~A 

k 23'"" '  TOOL  STEEL  (Harden)  tfj^*!? 

Shearing  Ring  Punch       Finish  J  ■    ^q^ 

Transfer  Plate  Bushing 
a&%\    k      PIS.  155  ..>i    ^.02Z« 

mT.-az5l'R.        ojway.--o.ss* 


...— .:.H-     U-Q875--4     1*^.-/3*.^    UW' 
Forming  Punch    ^SP**^?- I&^M        k 


-J 


Pie.  156   „ 

'  0.25  R. 


Forming  Die 


h-0.94-^  \  „ 
40.3fe--l/2"- -  *\   ■■Harten&grind*™* P" 

3.25-- -AtoOLSTEEL  Finish  J 

Q09">\  H     Shearing  Punch 

•f.  j)  J  Shearing  Die. 

'   -0.2S"R. 


>l   Wo.19"  -40.46\<'' 

->|    TOOL  STEEL  (Harden) 

FinishJ 

FIG.  157 


0.15-4  K 


FIG.  158 


Section  A-B 


FIG.  154 


[19] 


Commonly,  however,  the  hexagon  balls  are  made  on 
the  special  machines  and  the  spherical  ones  on  the 
press. 

The  mix  for  the  balls  is  melted  in  large  pots  and 
cast  into  ingots.  A  furnace  and  a  mold  are  shown 
in  Fig.  144.  The  mold  in  the  foreground  is  water  cooled 
and  so  made  as  to  be  swung  over  on  trunnions,  allowing 
the  cooled  ingot  to  drop  out. 

As  shown  in  Fig.  145,  the  wire  from  which  the  balls 
are  made  is  extruded  in  a  hydraulic  press.  As  the 
wire  issues  from  the  die,  it  is  carried  down  through  a 
trough  of  water.  At  the  farther  end  of  the  trough  it 
runs  over  a  large  grooved  pulley  carried  in  a  "floating" 
frame.  From  this  pulley  the  wire  is  run  back  toward 
the  press  and  is  automatically  wound  on  a  reel.  Friction 
drive  is  used  in  the  reel-turning  mechanism,  adjusted 
so  that  the  wire  will  be  closely  wound,  but  not  pulled 
so  hard  as  to  sever  it. 

In  making  balls  on  the  type  of  machine  shown  in 
Fig.  146  a  reel  of  wire  is  placed  in  the  bracket  and 
fed  into  the  machine.  A  cam-operated  slide  cuts  the 
wire  off  into  short  slugs,  which  are  carried  over  and  fed 
into  a  rotating  disk.  This  disk  carries  the  slug  between 
two  forming  punches,  which  compress  and  form  the 
lead  into  a  ball.  As  the  disk  again  indexes,  the  ball 
is  carried  to  the  next  set  of  dies,  where  the  flash  is 
trimmed  off.  An  extra  punch  in  a  slide  removes  all 
lead  particles  that  might  cling  to  the  dies  and  cause 
trouble  as  the  disk  indexes  to  the   different  positions. 


FIG.  163 
OPERATION  Z 


A,  Put  in  Tube  and  Diaphragm 


YY)7?7?>//J/^/rrr/y)Y/yyyy) 
B,  Put  in  18  Balls  andJ^Oz powdered  Resin 


'6V&^<<%U^///S.}V/(/.'sp** 


C,  Pour  in. 4  Oz.  melted  Resin 


D,  Putin  108  Balls  and  compress 


F,Put  in  Balls  to  make  Weight  12.625 lb. 
and  hammer  down 


G,  Pour  in  4  Oz.  melted  Resin 
FI6.I64 


FIG.  167 


Where  the  balls  are  made  on  a  punch  press,  as  shown 
in  Figs.  147  and  148,  twelve  are  made  at  each  stroke 
of  the  press.  The  12  reels  are  carried  on  a  slanting 
frame  in  such  a  way  that  any  individual  reel  may  be 
removed  and  replaced  without  disturbing  the  others. 
This  is  especially  necessary,  as  it  is  impossible  to  empty 
the  reels  all  at  once  on  account  of  varying  lengths  of 
wire. 

After  the  balls  are  formed  in  the  press,  they  drop 
into  a  tumbling  barrel  placed  close  to  the  machine,  as 
shown  at  the  back  in  Fig.  148.  The  balls  are  tumbled 
in  this  to  remove  the  flash,  the  rubbing  together  accom- 
plishing the  desired  result. 

After  the  case  has  been  washed  in  hot .  soda  water, 
the  interior  is  painted  and  then  is  ready  for  assembling 
and  for  receiving  the  balls.  The  standard  shop  directions 
for  this  operation  are  as  follows : 

Make  sure  that  the  diaphragm  seats  very  firmly  on  the 
shoulder;  pour  in  0.25  oz.  powdered  resin  to  seal  joints  and 
shake  down  well  to  fill  all  cracks.  The  powdered  resin 
becomes  plastic  when  the  melted  resin  is  poured  in. 

Put  in  one  layer  of  balls  (18)  and  pour  in  0.4  oz.  of  melted 
resin.  Put  in  108  balls  and  settle  by  a  pressure  of  6  tons. 
Pour  in  2.25  oz.  of  melted  pure  white  commercial  naphthalene. 
Put  in  sufficient  number  of  balls  to  bring  the  weight  to  12.625 
lb.  Drive  down  with  mallet  and  pour  in  4  oz.  of  melted  resin. 
After  the  mass  has  thoroughly  cooled,  face  off  matrix  so  that 
the  depth  from  end  of  case  shall  be  0.35  in.  to  allow  for  screw- 
ing in  of  head,  which  should  bear  down  hard  on  matrix. 


Final  Operations 

Assembling 
operation  1.    wash  case  in  hot  soda  water 

Number  of  Operators — One.  Description  of  Operation — 
Operator  places  case  in  solution  until  grease  is  cut  off,  then 
rinses  in  hot  water  and  drains  it.  Apparatus  and  Equipment 
Used — Tongs,  Fig.  161;  tank  of  Wyandotte  metal-cleaner  solu- 
tion; tank  of  hot  water.     Production — 350  per  day. 

OPERATION  2.     PAINT  INTERIOR 

Transformation — Fig.  162.  Number  of  Operators — One. 
Description  of  Operation — Operator  chucks  case  and  applies 
the  paint  inside  so  as  not  to  daub  up  the  threads;  machine 
runs  140  r.p.m.  Apparatus  and  Equipment  Used — Smali  special 
machine,  Fig.  163;  pot  of  asphaltum  varnish;  long-handled 
brush.     Production — 1000  per  day. 

OPERATIONS    3-A,    3-B    AND    3-C.      ASSEMBLE    TUBE    AND 
DIAPHRAGM,    FILL   CASE,    COMPRESS   BALLS 

Transformation — Figs.  164  and  164-A.  Number  of  Oper- 
ators— Two.  Description  of  Operation-1— First  operator  puts  in 
diaphragm  and  tube,  making  sure  the  diaphragm  seats 
firmly;  then  he  pours  in  \i  oz.  powdered  resin;  next,  he  places 
a  layer  of  18  balls  on  the  diaphragm  and  pours  in  0.4  oz.  of 
melted  resin;  108  balls  are  put  in  and  pressed  down  by  second 
operator  with  6  tons'  pressure;  21/£  oz.  of  melted  purs  white 
commercial  naphthalene  is  poured  in;  sufficient  balls  are  next 
added  to  bring  weight  to  12.625  lb.;  these  balls  are  driven 
down  with  mallet,  and  4  oz.  of  melted  resin  is  poured  in. 
Apparatus  and  Equipment  Used — Watson-Stillman  hydraulic 
press.  Fig.  165;  scale,  Fig.  166;  melting  pots  for  resin  and 
naphthalene,  Fig.  167;  mallet.     Production — 340  per  8-hr.  day. 

OPERATION   4.      CUT  OUT  SURPLUS  RESIN 

Transformation — Fig.  168.  Machine  Used — Small  lathe, 
Fig,  169.  Number  of  Operators  per  Machine — One.  Work- 
Holding  Devices — Special  chuck,  Fig.  170.  Tool-Holding 
Devices — Shank  for  cutter,  Fig.  171.  Cutting  Tools — Resin 
cutter,  Fig.  172.  Cut  Data — 250  r.p.m.  Gages — Depth,  Fig.  173. 
Production — 1000  per  8  hr. 


Stamp  Name  of  Shrapnel,  Part,  Place  of 
Manufacture  and  Date  (Year) 

->V25&- 


Stamp  Name  of  Shrapnel,  Part,  Place  of 
Manufacture  and  Date  (Year) 


One  0.5x1.0  Sfd.  Steel  Setscrew 
One  0.228*2.5" Drill  Rod,  Drive 


Chuck 


TOOL  STEEL  n 
FinishfiQOI 

FI6.I7I 


For  0M"(§)'kZ5" Sfd  Steel  Setscrew} 
FIG.  172 


o 


J  -.\<:\as"Drill 


^     i  Bushing 

1 

One  A  -1.987" For  3.0"Shrapnel 
"  >"2.93f  -  2.95"    ■> 


L.„ t/j! yJ       Stamp  Name  of  Shrapnel,  Part,  Operation, 

Name  and  Size  of  Machine 

■MACHINE  STEEL  Finish  ft  0.0l" 

FIG.  170 


'•0.3l2?i)"Force 

MACHINE  STEEL 
FinishfiQOI"  j 
Case  Harden   t  • 


■4.5- 


-  0-9"-'^ QI25" 0.6" Steel  Pin  Drive 


& 


OPERATION  4 


Stamp  Name  of  Shrapnel,  Part,  Dimension  gaged. 
Place  of  Manufacture  and  Date  (Year) 
FI6. 173 


[21] 


OPERATION   5.      MOISTEN   THREADS   OF    HEAD   WITH 

COSMOLINE,    ASSEMBLE   HEAD    TO   CASE    AND 

INSERT  INNER  TUBE 

Transformation — Fig.     174.       Number     of     Operators — One. 

Description  of  Operation — Operator  brushes  a  little  cosmoline 

on   threads   of  head,    places   case   in   bench    holding-   block   and 

screws  head  into  place,   Fig.   175;   he   then   puts   in   inner  tube 

and  hammers  it  in  place  with  hammer  and  special  punch,  Fig. 

176.     Apparatus  and  Equipment  Used — Holding  block;  wrench, 

Fig.   177;  punch,   Fig.  178;   hammer.     Production — 515  per  day. 

OPERATION  6.     PIN  HEAD  TO  CASE 

Transformation — Fig.     179.       Machine    Used — Small    drilling 

machine,    Fig.    180.      Number   of   Operators   per   Machine— One. 

Tool-Holding    Devices — Drill    chuck.       Cutting    Tools — No.    31 

twist  drill.     Special  Fixtures — Fixture   to  hold  case,   Fig.    187. 

Production — 600  per  8  hr.     Note — Pins  are  supplied  of  correct 

size  and  are  driven  in  by  hand. 

OPERATION  7.  TURN  BOURRELET  (WHEN  CASES  ARE 
FINISHED  BY  OUTSIDE  CONTRACT) 
Transformation — Fig.  182.  Machine  Used — Le  Blond  17-in. 
lathe.  Number  of  Operators  per  Machine — One.  Work-Hold- 
ing Devices — Special  chuck.  Fig.  184;  steadyrest.  Cutting 
Tools — Left-hand  lathe  tool.  Cut  Data — 50  ft.  surface  speed. 
Special  Fixtures — Split  bushing;  form  and  form  follower,  Fig. 
183.  Gages — Maximum  diameter,  ring,  Fig.  43;  minimum 
diameter,  ring,  Fig.  44;  diameter,  nose  thread,  plug,  Fig.  45. 
Production — 180  per  8  hr. 

In  all  cases  where  two  parts  are  screwed  together  it 
is  the  practice  to  put  on  enough  cosmoline  to  coat  the 
threads.  This  is  simply  slushed  on  with  a  small  brush. 
With  the  threads  moistened  with  cosmoline,  the  head  is 
screwed  into  the  case,  using  the  special  wrench  and 
holding  block  shown  in  Fig.  175. 

Following  this  the  same  operator  forces  in  the  inner 
tube  with  a  punch  and  hammer,  as  shown  in  Fig.  176, 
the  two  transformations  A  and  B,  Fig.  174,  showing  what 


is  done.  Details  of  both  the  wrench  and  punch  are  given 
in  Figs.  177  and  178. 

The  pinning  of  the  head  to  the  case  is  done  by  one 
operator  who  first  drills  the  two  holes  in  a  small  drilling 
machine,  using  a  special  holding  fixture  as  shown  in 
Fig.  180,  the  details  being  given  in  Fig.  181.  After 
drilling  the  holes  he  drives  in  small  pins,  which  are 
bought  in  quantities  for  the  purpose. 

No  accurate  spacing  of  the  pin-holes  is  necessary,  the 
operator  drilling  them  approximately  opposite  each  other. 

The  turning  of  the  bourrelet  indicated  in  operation  7, 
is  only  done  where  the  cases  are  finished  by  outside 
contractors,  as  when  they  are  machined  at  the  arsenal  the 
bourrelet  is  finished  along  with  the  point. 

The  grooving  for  the  waterproof  cover  is  done  in  a 
lathe,  the  shell  being  held  in  a  special  screw  chuck,  Fig. 
187,  in  conjunction  with  a  revolving  tail  center,  Fig.  189, 
the  cutting  tool  used  being  shown  in  Fig.  188. 

Painting  of  the  outside  is  done  by  chucking  the  shell 
in  a  lathe  and  applying  the  paint  in  broad  bands  with 
a  brush,  the  operator  after  a  little  practice  judging  the 
width  of  the  bands  with  his  eye.  On'  large  shells  they 
are  held  in  a  vertical  position  on  a  rotating  fixture,  the 
operator  using  pointers  on  an  upright  piece  to  indicate 
the  width  of  the  bands  until  accustomed  to  his   work. 


gp^^^p^^^^^^^??^ 


wm?M&zmmp77777, 


-Y/v/////m& 


FIG.  174 


D 


Body 
FORGED   STEEL 
tOOl" 


QSTsUVsMfiHstirMead  ^shft00l"U/.7"J  ^25" 
Steel  Screws 

■0.375  "Tap  Std030eep. 


FIG  175 


FIG.  176 


Bushing  for  5.8  Shrapnei 

„,_./>■  ,,       MACH.  STEEL  c-    ■.  «..,._. 

03"Dee  (Ca5e  fiarden}  h*/*1   nmsh/±a0f 


■>*04 

4"-- - -J 

Punch 
TOOL  STEEL  (Harden  Point) 

Finish  ft  0.0/" 

A = 0.25 "fbr 295  "and  3  "Shrapnel 
A  =033""  3.6,"4.7"»6"      » 

FIG.  178 


Bushing  for  2.95  &  3  Shrapnel 
(Case  //ara/enjgr 


^—>-i*(l75«-Ream\ 


Bushing 
MACtl.    STEEL 
(Case  Harden)    n 
A°9.4'R  B- 3.4" for 4.7  Shrapnel 
A  =  IZ"R.B~3.5" ••   6"       tf 


Cap 
MACtt  ste:el 

0.75"x//"steef  Rod  Drive 
0375**3.25"  -    Pin       » 


OPERATION      5 


Stamp  ■■  name  of  shrapnel, part 
operation,  place  of  manufacture 
and  date  (/ear) 

FJGI77 


[22] 


The  paints  used  are  for  two  purposes:  (a)  To 
protect  metal  from  corrosion,  and  (b)  to  identify 
different  kinds  of  projectiles  and  contents.  Eed  indicates 
a  bursting  charge,  or  high  explosive;  gray,  forged-steel 
case ;  yellow,  explosive  of  low  power ;  olive  green,  cast  iron ; 
and  so  on.  In  some  cases  slushing  oil  is  put  on  back 
of  the  band;  but  where  it  is  not  to  be  immediately 
assembled  with  the  cartridge  case,  red  paint  is  used. 

The  various  colors  and  the  method  of  mixing  are  here 
given,  the  exact  proportions  being  given  in  each  case. 


/Front  Block 


IT) 


FIG. 180 

Q375"TapSfd 
0.65'Deep 


— 1   //////**        - — vi     \=/ 

J!!  ;!(hf°pjf/^rj  \p^ — - 


■>w> 


Base 


.:.    \<X  §  f  if..-  -Force .  r;. 

05%^07&'- 4.0' ^75^--2.0"-^l.0%&       tori  J  k8SU-f-32E»" 

MX** 4.75°- ----,->k-  0275— MO?*  .   ,  U \ 50 ** 

H " 9.5 ^  For 0,575*10  SM  Filisterhead  Steel Screws 

MACHINE  STEEL 

fig.  i8i 

OPERATION  6 


Body  (Black) — 1  Gal.: 

Lampblack,    dry    1  lb. 

Linseed    oil,    raw ^  gal 

Texene    A  gal 

Japan    drier    fa  gal 

Copal   varnish    . ; fa  gal 

Cast  Iron  (Light  Olive  Green) — 1  Gal.: 

French   yellow   ocher,   in   oil T?i  lb. 

Lemon  chrome  yellow,  in  oil 15  oz. 

Chrome  green,  in  oil 6  oz. 

Lampblack,    in    oil    3 

Linseed  oil,   raw    fa 

Texene    % 

Japan    drier jfo 


oz. 

gal. 

gal 

..  Kal 

Copal  varnish &  gal 

Powder    ("Vermilion) — 1   Gal.: 

Deepfast    vermilion,    in    oil.... 

Red   lead,   dry    

Whiting,    dry    

Linseed  oil,  raw   

Japan    drier    


2  lb. 
7  lb. 

4y2  lb. 
%  gal. 
•hs  gal 

Priming  Coat  (Red) — 1  Gal.: 

Red  lead,  dry  10  lb. 

Whiting,   dry    4  lb. 

Linseed    oil,    raw    %  gal. 

Japan  drier    fa   gal. 


Explosive  D    (Deep  Yellow)- 
French   yellow    ocher,    in    oil. 


-1  Gal.: 

r  icuuii     jciiuw      uvuci,        11      un I  732    ID. 

English  Venetian   red,   in   oil 3  oz. 

Lemon    chrome    yellow 4  %  lb. 

Linseed  oil,   raw    %  gal.. 

Texene     fa  gal. 

Japan    drier    3*5  gal. 

Copal  varnish ^2  gal. 

Cast  Steel   (Warm  Gray) — 1  Gal.: 

White   lead,    in    oil 

Whiting,    dry    4 

French  yellow  ocher,   in   oil 

Lampblack,  in  oil    

Lemon  chrome  yellow,  in  oil 

Linseed    oil,    raw    

Texene    

Japan    drier    

Copal   varnish    


8  lb. 
%  lb. 
%  lb. 

y2  oz. 

1  oz. 

fa  gal. 

fa  gal. 

A  gal. 

fa  gal. 

Forged  Steel   (Blue  Gray) — 1  Gal.: 

White  lead,  in  oil 7  lb. 

Whiting,    dry    5  lb. 

Lampblack,    in    oil 3  oz. 

Linseed  oil,   raw    %  gal. 

Texene    &  gal. 

Japan    drier fa  gal. 

Copal    varnish    A  gal. 


\*Q75>\ 


<—!25-»f-  /<?'->K 225*- ->|< l.75-->\<-  -1.25 --> 

\j--For  0.512  (§)  Filisterhead '  St'd.  Setscrews. 

rQ_<§  Q       <8 


'Tor  OS  Bolt 


■7.5- 


n    -For  0.5  Bolt 


FIG.  182 


Sp!i+  Bushing 

MACHINE  STEEL 
Finishf±0.0l 


Stam  Name  of  Shrapnel,  Part,  Place  of 
Manufacture  and  Date  (Year) 


k- 1375 ■-: 


■2.5 M 


MACHINE 
STEEL 

Finish/ 
t0.005 
Harden 

■i 

Form 


yo/ 


Harden  End. 


Body 

CAST  IRON 
nnishfiQOI 


Expansion  Spring 


Groove,  for  Faceplate  of 
Lathe  to  suit  Chuck 


FIG.  184 
OPERATION  7 


A- 2.98  for  5- inch  Common  Shrapnel 
A'2.935'"  2.95-inch  Shrapnel 


[23] 


The  powder  charge  is  loaded  in  the  machine  shown 
in  Fig.  149.  The  shells  are  placed  in  rotating  holders, 
and  a  funnel  is  swung  over  them.  The  powder  charge 
is  then  poured  into  the  funnel  and  runs  down  through 
the  center  tube  into  the  powder  chamber.  A  second 
operator  then  takes  the  shell  and  pokes  a  small  wad  of 
gun  cotton  down  into  the  center  tube  to  hold  the  powder 
in  place. 

Following  the  loading,  the  shells  go  to  a  gang  of  three 
men,  who  put  on  the  fuse.  The  first  brushes  cosmoline 
on  the  threads  and  partly  screws  in  the  fuse.  The 
next  man  sets  the  shell  in  a  bench  chuck,  Fig.  195, 
screws  down  the  fuse  and  locks  it  in  place  with  punch  and 
hammer.  The  third  man  places  the  fuse  setter  over  the 
fuse  and  sets  it  to  the  safety  point. 

From  this  gang  the  shell  goes  to  the  crimping  machine, 
Fig.  19?.  The  operator  paints  the  cover  groove,  slips  a 
brass  waterproof  cover  in  the  holder,  places  the  shell 
in  the  fixture  and  starts  the  machine.  The  disk  roller 
revolves  around  the  head  and  securely  crimps  the  cover 
in  place.  Following  this  the  edges  of  the  cover  and  the 
junction  with  the  shell  are  painted  by  hand  with  asphal- 
tum  varnish  in  order  that  the  joint  may  be  water-tight. 


OPERATION  8.  GROOVE  FOR  WATERPROOF  COVER 
Transformation — Fig.  185.  Machine  Used — Le  Blond  17-in. 
lathe,  Fig.  186.  Number  of  Operators  per  Machine— One. 
Work-Holding  Devices — Special  screw  chuck,  Fig.  187.  Cut- 
ting Tools — Special  lathe  tool,  Fig.  188.  Cut  Data — 50  ft.  sur- 
face speed.  Special  Fixtures — Revolving  center,  Fig.  189. 
Gages — Position,  scratch  gage,  Fig.  190;  position  gage,  Fig. 
191.     Production — 600  per   8   hr. 

OPERATION  9.  PAINT  OUTSIDE 
Transformation  —  Fig.  192.  Number  of  Operators  —  One. 
Description  of  Operation — Operator  chucks  butt  end  of  case 
in  small  lathe  and  applies  paint  with  wide  brushes.  Apparatus 
and  Equipment  Used — Pot  of  black  paint,  pot  of  yellow  paint, 
two  brushes.  Production — 800  per  day.  Note — Machine  runs 
250  r.p.m. 

OPERATION  10.  LOAD  POWDER  CHARGE 
Transformation — Fig.  193.  Number  of  Operators — Three 
(two  loaders  and  a  trucker).  Description  of  Operation — Cases 
are  placed  in  the  revolving  fixtures  shown,  and  1180  gr. 
shrapnel  powder  is  poured  in  through  the  funnels;  next,  a 
wad  of  gun  cotton  is  pushed  down  through  the  tube  to  retain 
the  powder  and  assist  ignition;  powder  is  measured  by  means 
of  the  little  dipper  shown  on  the  bench;  the  cases  rotate  about 
200  r.p.m.  as  the  powder  runs  in  through  a  ^3-in.  opening  in 
the  funnels.  Apparatus  and  Equipment  Used — Loading  fix- 
tures, Fig.  149;  measuring  dipper;  trucks.  Production — 2200 
per  day  per  gang. 

OPERATION   11.      BRUSH  COSMOLINE  ON  FUSE   THREADS 
Number  of  Operators — One   (three  in  gang).     Production — 
1200  per  day.     Note — Three  men  do  operations  11,  12  and  13  in 
succession. 

OPERATION    12.      SCREW   IN  FUSE   AND  LOCK 
Transformation — Fig.   194.     Number  of  Operators — One    (in 
gang    of    three).       Apparatus     and     Equipment     Used — Bench 
chuck,  wrench,  punch  and  hammer,  as  shown  in  Fig.  195.    Pro- 
duction— 1200  per  day. 


a5tmz - 


T^n 


I 


■Of/Grooves 0/l'mde,x0.05"deep,xl,5''/onq  >\QS"\t~- 


0.625R: 


FIG.  185 


■0.29 


MACti.  steel 
(Case  Harden) 
0.25x0.375'Std.  Head/ess 
Setscnew 

A°2.4"for2.95"&3"Com.Shrap     n/g/'A 
A  =Z55"»  3"  /I.E. Shrapnel '     pf-i/r 

FIG.  189 


Ba//s  held  in  Retainer- 
by  two  Set  Mar  Ms  „    , , 
0J87"(2")  hardened  Ball  Retainer 
KSteel  Balls /Q„    BRONZE 


Section  B*B 
M 


Holder 


finish/tO.OI 


MACh.  STEEL 

4-0.2SxO.3l2U/std.  Headless 

Steel  Setscrews 


FIG.  187 


Ring 
TOOL  STEEL  (Harden) 
Used  on  l6"/7ather  Lathe 

Stamp  :name  of  shrapnel, 
part,  name  and  size  or  machine 


*^  k —  A3    — >J 
SS  Scratch  Pin 
§    TOOL  STEEL 
^     (Harden) 


It  <5S 

0.2*\   Y--^_   finish/ 0.01 


MACh.  STEEL 
(Case  Harden) 

4.5" --  —  - 

Body      0.19x0.1  "Std  Headless 
FIG.  190     steel  Screiy 


.--*  K-02 


0./2&  k 


Stamp: name  of  shrapnel, 
part,  operation,  place  of 
manufacture,  dimensions 
gaged  and  date  (year) 


"2 
0.I25R 


'jpjft**-- 

SAW  STEEL 
(Harden) 
FIG.  191 


■3.75   >\ 


OPERAPON     6 


[24] 


OPERATION  13.     SET  FUSE  TO  SAFETY  POINT 
Number  of  Operators — One  (in  gang  of  three).     Description 
of  Operation — Operator  places  projectile  in  chuck,  places  fuse 
setter  over  the  fuse  nose,  as  shown  in  Fig.  196,  and  sets  fuse 
to  safety  point.     Production — 1200  per  day. 

OPERATION  14.     CRIMP  ON  WATERPROOF  COVER 
Transformation — Fig.   196.     Machine  Used — Lathe,   Fig.   197. 
Method    of   Operation — Operator    spreads    asphaltum    paint    in 


Yellow 


Black 


Loading 

Powder        Pulling  In  small  Plug 

Chamber      0f  Qun  Qoffon  \ 


-3 >H 

FIG.  192 
OPERATION  9 


FIG.  193 
OPERATION  10 


the  groove  with  a  brush,  presses  on  waterproof  cover  and 
places  in  machine,  as  shown;  he  then  sets  lever  so  that  roller 
will  press  metal  of  cover  into  groove  and  starts  machine; 
afterward  he  coats  junction  of  cover  and  head  with  asphaltum 
paint  to  make  water-tight;  another  slightly  different  form  of 
machine  is  shown  in  Fig.  198;  these  machines  run  about  50 
r.p.m.     Production — 700  per  day. 

Operations  That  Have  Been  Omitted 

In  the  foregoing  article  a  number  of  operations  of 
considerable  importance  have  not  been  described  in  detail 
for  the  reason  that  they  are  the  same  as  those  on  the 
3-in.  common  steel  shell,  which  will  be  described  in  a 
subsequent  article.  For  instance  the  making  of  the 
copper  band  will  later  be  given  in  detail  from  the  time 
it  is  cut  from  copper  tubing  through  all  the  steps,  such 
as  pickling,  planishing,  heating,  pressing  into  place  and 
finishing. 

The  night  tracer  will  also  be  described  and  will  be 
found  of  considerable  interest.  These  tracers  are  made 
from  brass  rod,  in  automatic  machines,  so  that  the 
machining  is  not  as  interesting  as  the  process  of  loading, 
which  must  be  so  arranged  that  the  trail  of  fire  does  not 
show  until  the  shell  is  some  distance  from  the  muzzle  of 
the  gun.  Otherwise  the  position  of  the  piece  would  be 
revealed  to  the  enemy  and  afford  a  well-located  target. 
The  explosion  of  the  propelling  charge  first  ignites  a 
slow-burning  powder,  which  in  turn  sets  off  an  ignition 
mixture  followed  by  the  blazing  of  the  illuminant. 


SectionC-D 
FIG.  199 


[25] 


iiimiiiiiiiiiiiiiiiiiiiiiiiii'iiiiiimiiiimriii iiiiiiiiiiiiiiiimiiiiiiiiiiiiiiiiiiiiiiiii iitiiiimi iiiiuiiiiiitiiiiiitiiiiaiiiiiiiiiiiiiiaiiiiiiiiiitiiiiiiiiiiiiiiitiJiiitiJiiiiiiiiiiiiiiiiiitiiiiiifiitiiiiitiiiiiiitiiiiiiiiiitiiitiiiiiiiiiiiiiiiiiiiiiifiii  ■ainiitiiiiciiiiiiiit  tiiiiiint  iiiiiitiiti|^ 

I  United  States  Munitions*  I 

The  3-In.  Common  Steel  Shell 


iiiiiiiiiiiiiiiiiiiiuiimiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiniiiiiiiiiiiiiiiiiiiiMiiiiiiiiiiiiiiiiiiiiiiiiimiiiiiiiiiiiiiiiiiiiiiiiiiiim 


United  States  3-In.  Common  Shell 

The  high-explosive,  or  common,  steel  shell,  as  it  is 
called,  is  of  the  solid-point,  base-detonating  type,  which 
explodes  only  on  impact  and  cannot  be  set  for  time  ex- 
plosion. The  explosive  carried  by  the  shell  is  trinitro- 
toluol, which  is  forced  into  the  interior  of  the  shell  under 
heavy  hydraulic  pressure.  The  base  detonator  that  causes 
the  shell  to  explode  when  it  strikes  is  so  made  that  it  only 


shell's  being  dropped,  would  not  be  caused  by  the  action  of 
the  detonator  mechanism  in  any  case  unless  the  shell  was 
fired  from  a  gun,  as  it  is  the  rotation  of  the  shell  in 
flight  that  sets  the  mechanism  for  active  operation. 

The  specifications  for  the  steel  used  in  these  shells  are 
practically  the  same  as  given  for  the  3-in.  shrapnel;  but 
since  it  is  impracticable  to  determine  the  contour  of  the 
front  end  of  the  cavity  after  the  forging  is  closed  in  at 
the  base,  this  part  is  inspected  by  the  inspector  at  the 


Stamp,  with  0./25  letters  and  figures, 
tot  number  or  she/I,  purchase  order, 
date  of  issue  of  purchase  order  (fiscal 
yeqr)  and initials  of  manufacturer 


Rough  machine  outside 
diameter  concentric  with 
cavity  before  closing  in 
base 


>       I 


Uc./S*t42S'A 


-0.1" 


FORGED    STEEL 


3 


-  3.05t0.05 

k""  z'tQOS" 
g35"+O.I5„ ..      .        A.  7c»1-0.3".... 

yab-o.os"      ZJ^t  Z5-0.0 

k - - -  **?i!ff'- - - < 

FIG.  1.     THREE-INCH  COMMON  SHELL.  FORGING 


becomes  active  after  the  shell  is  fired  from  the  gun.    This     works  after  the  projectiles  are  punched  and  before  the 


makes  possible  the  safe  handling  of  loaded  shells,  which 
might  be  dropped  point  down  for  some  distance  without 
exploding;  the  explosion,  if  one  should  occur  from  the 

•Copyright,  1917,  McGraw-Hill  Publishing  Co.,  Inc. 


closing-in  operation.  Details  of  the  forging  as  received 
at  the  Government  arsenals  are  given  in  Fig.  1.  The 
finished  projectile  is  shown  in  Fig.  2.  As  with  the  3-in. 
shrapnel,  10  per  cent,  of  these  shells  are  fitted  with  night 


Crimping..*  0.2  -^QI5^-  -  03-  >¥0m 
6roovl    *~~35?~j\  Mo5"R.      \AM\R. 


Crimping  and 

Lubricating 

Groove. 


FORGED  STEEL 


Stamp  with  O.O62"fj0  letters  &  figures. 

lot  no.  of  she/ J,  purchase  order,  date  of 

issue  of  p.o.(fiscal year)  and  initials  of 

\        manufacturer 


Volume  Cavity  Empty  2268  Cu. In. 

-  Fuse  in  Place  '18.49     - 

-  Without  Fuse  22.4 

-  With        »     21.0 


r 

\<U  i0.05 


\-5.0  i  0.1  to  Center  of  Gravity— *, 

- l-97/"t0.l"- 4—3=— 

— ->^-—~\- 3.05 1 0.05 
■>luol 
Compress  under  Pressure 


6.66  i0.05- 


25  Scores 
per  Inch, 
O.I5"Deep 


Scores 


3  Notches  eauallv  spaced  /Z  TWs.perlnch.tS.Sld  Lw/^fi-J  10  per  cent,  of  each  lot  will  be\f  I  L.^  ..>(<...._    A 

3?r™roSt         IfH^MstoTjto***?*^       fitted  with  mght  tracers?  \    '6^005*  f 


'mtihes'forTocAing       lightly  with  Cosmoline    L.  .^.i.^f^ 


S» — 3.52 1 0.04- 


jkt 


523±ar~~ 

■ -1 1.6" to/- 


-J 


H tf- 


—  4. 


.Of- J 


IfcStwp  with' 0.062  fg)  letters  &  figures,  PA  lot  no.  &  ammunition  lot  no.  The  stamping  prescribed  may  be  rolled  in  on  band, 
if  also  stamped  en  base  within  the  groove  in  lieu  of  stamping  in  front  of  band 

Finish  OutsidkftQOI,  Rough  Inside  except  where  marked f>  Coat  Inside  with  Non-acid  Paint 
FIG.  2.     DETAILS  OF  COMPLETE  PROJECTILE? 


[26] 


PIG.   3. 


CENTERING  BASE  OF   FORGING   IN   A   LATHE 
FITTED  WITH  CROSS-SLIDE  TURRET 


FIG.    4.    ROUGH-TURNING  THE  NOSE  OF   THE   CASE 
ON  A  LATHE 


FIG.    5.    ROUGH-TURNING   BODY,   USING   A   SPECIAL 
DRIVER  AND  CENTER 


FIG.    6.    FINISHING   THE   BASE   ON  A   CLEVELAND 
AUTOMATIC   SCREW   MACHINE 


FIG.  7.    ROUGH-FORMING  AND  FINISHING  THE  POINT 
AND   BOURRELET   ON  AN   AUTOMATIC 


FIG.    8.    FINISHING    THE    BODY,    WITH   CASE    HELD 
BETWEEN  SPECIAL  CENTERS 


FIG.  9.    NOTCHING  THE  BASE  ON  A  HAND   MILLER 
FITTED  WITH  SPECIAL  FIXTURE 


FIG.  10.    BORING  THE  INTERIOR  ON  A  LATHE  USING 
COMMON  BORING  TOOL 


[27] 


wm 


L2 


/////////// 


FIG.  II 


HIGH  SPEED  STEEL 
(Harden) 

Finish j±aor 


MACHINE 


STEEL         ffL     .,,1      I    .   .~c-H 


sK 


fCose  Harden)  Finish Jl±0.0f, 

O.Z75"X0.875"Sfd  5teel  5etscrews\< 3--- 

Holder 

PI-  ,,  Harden 


■9.81'Ma*. 


JJt 


-361  Mia 


0.5%    I 

U 


*y-0/f  ^MaxEize) 

Z7r///   Mot. (Sizel±Use thisEdpe  ForWarp  6gge 


t*ai25"' 


1     Max.Radiusof  Band  Minus       J&~    This  Edge  must  be  ground  strd'ighr^^\To  bear  on 

I    Max.Radiusof Bourre[et_  _  _  •  gr" _    X    ,7c">\Bourre,e^ 

" SAW STEEL  Finish J ±0.005''"' 
Depth  of  Cavity  Rod  and  Warp  Gage 

A 


-605- 


>tfO.I2'D 


-j§- 


FIG.I2 


■1.2- 


Aos\*-  -*ifl8Al< - 

Hr- — - —S£ 

SAW  STEEL  Finish/ ±0.005 
Cross  Bar  (Depth  of  Cavity  Rod) 
OPERATION  I        FIG.  14 


a, 


«V5 

Section 
A-A 


. 


• 


JHprcten 


-~—&55 

Body 

7<?<?z  5/^/.  (Forge) 

F/nish/±0.05r 


' /  y  y  /  -j  's  s-s  v-^^^-L 


8a//s  held  in  Retainer 
by  Two  Set  Marks, 


A =3675  B = 3.f'3M.FShrapnet 
A  =3.875" B= -S/r  3"Common    » 
A  =3.675"  B= 3. 05,"  2.95  "Shrapnel 


■H     \<-08±0002 


_^fsfe$Fs 


0.25  R 

A    ^ 

MarkOiJ-~\--' ' '\  O-BapStcf.  for 
Case     Holder  ^H    rf  ^ 

met/.  ST£SL  (Case  t/arden)       /^-a-^E^ 
„,*    ^£±0.05"  0.05^f^^20t/.S.Sttt.rnr^. 

0.25x0.37S"Sttif1ead/ess  Steef  as™%   perm.       Race  Rlnc. 

Holding  Screw  702:  5/zrz 

7P0Z  sr£l:L(/1arc/en)  TfardenWO/" 

r/n/sn/saot" 


:f 


...   §&  "H  V-- 0.25 ±0.002" 
-^  §§  Race  Ring 

_£?  ;wz  s/zzz    . 

5*  ttarcfentO.O/ 


\->',<- -025  ±0.002 


if. 

Ball    Retainer 

.,  BRONZE  „ 
Firyshb±0.0t 
25  Q25r^Sfee/ Bat/5 


Set  Screw 


FIG.  20 


OPERATION  1.  ROUGH-FACE  BASE 
Transformation — Fig.  11.  Machine  UseCt — Prentice  upright 
drilling  machine.  Number  of  Operators  per  Machine — One. 
Work-Holding  Devices — Table  knee  clamp,  Fig.  12-A;  bed- 
plate center,  Fig.  12-B.  Cutting  Tools — Facing  cutter  with 
inserted  blades,  Figs.  12-C  and  13.  Cut  Data— Spindle  runs 
65  r.p.m.  Coolant — None.  Average  Life  of  Tool  Between 
Gnndmgs — About  y2  day.  Gages — Depth  of  cavity,  Fig.  14. 
Production — 400  per  8  hr.  Note — Operator  must  face  base 
close  to  the  maximum  limit  to  allow  for  finish. 

OPERATION    2.      CENTER 

Transformation — Fig.  15.     Machine  Used— Reed  18"-in.  lathe, 
tig.     3.       Number    of    Operators    per    Machine — One.       Work- 


Holding  Devices — Steadyrest;  three-jaw  universal  chuck. 
Tool-Holding  Devices — Turret  toolholder;  Fig.  16.  Cutting 
Tools — Rough-centering  tool,  Fig.  16-A;  centering  reamer. 
Fig.  16-B.  Cut  Data— 170  r.p.m.  Coolant — None.  Average 
Life  of  Tool  Between  Grindings — About  2  days.  Gages — None. 
Production — 400  per  8  hr. 

OPERATION  3.  ROUGH-TURN  POINTS 
Transformation— Fig.  17.  Machine  Used — Le  Blond  17-in. 
lathe,  Fig.  4.  Number  of  Operators  per  Machine — One.  Work- 
Holding  Devices — Drive  dog  and  centers;  red  lead  on  tail 
center.  Tool-Holding  Devices — Toolpost.  Cutting  Tools — 
Lathe  turning  tool.  Number  of  Cuts — Cuts  off  scale  and  cleans 
up  entire  point.  Cut  Data — 95  r.p.m.  Coolant — None.  Gages 
— None.     Production — 200  per  8  hr. 


[28] 


tracers.    The  weight  of  the  complete  projectile  is  divided 
as  follows: 

Lb. 

Shell   (empty),  steel 12.355 

Band,  copper 0.15 

Fuse    1.38 

Base   cover    (complete) 0.215 

Trinitrotoluol  , 0.9 

Total  weight v 15  ±0.15 

LIST   OF    OPERATIONS   ON   THE    CASE 

1.  Rough-face  base 

2.  Center 

3.  Rough-turn  point 

4.  Rough-turn  body 

5.  Finish-machine  base 

6.  Finish  point 

7.  Finish-turn  body 

8.  Notch  base 

9.  Bore  interior 

10.  Rough  base-cover  groove 

11.  Finish  base-cover  groove 

12.  Assemble  band 

13.  Turn  band  on  lathe 

13-A.   Turn  band  on  special  machine 

14.  Resize  threads  and  counterbore;  inspect  all  over 

15.  Sandblast 

16.  Hydraulic  test 


tYR  Bjh" 


I  MJT 


'     I     Vt- 1.808" Mi,..    . 

U Z«5'- J0"*"- 

iAWS  TBI  Finish/  tQOl" Harden 

FI6.40 


■*\  am- 


T 


,  025  K 
0.201  drill. 

'      b 


0.55^-12  ■> 


•3    ■*>*'* 


PART 

A 

B 

c 

Band  Seat 

2.81 

286 

U3 

Body 

?% 

*• 

1.5 

Bour relet 

199 

,,,.,: 

IS 

Rear  of  Band 

2  "65 

2<J7i 

'If 

\*-i.o"- 

SAW  STEEL 
Finish  ft0.0l" Harden 

FIG.44 


OPERATION  2 


FIG.  I7.0P.3 


I 


K/  >\/6UxS.Sttf.7hreads 

nrri  I     vy        per  117. 


J?^M2"(§)TapStii. 


Assembled     Views 


0.125^^-0.062" 


r/  >! 


$   J6US.Sfcf.Thrd.per in. 

Adjusting  Screw 

MACtl.  STEEL 
(Case  flarden) 

§•£       $ 


l\, 

1  >», 

{(■ 

* 

K-f.3f"  -H 

Approx.64\\. 

rJ 


^0.375" 
Guide  Screw 
MACH.  STEEL 
(Case  fiarcfen) 


Angle  fo  suit  Poinf^  ^0.125" 
Jaw 
TOOL    STEEL 
*L  (fiarcfen) 

0.25-tA  k^ 
Shield 
bra  ss 


OPERATION    4 


rinishjrtO  0/ 
FIG.  19 

T 


03S-> 


\        7,~/20° 
V.3/2  Tap  Stcf. 

A-2.25,"6perin.  tor  Reed or  l7"LeB!oncf 
A=2,875r'$»    »     '    Zf'Le Blond  Lathe 

Body 

„  MACH.  STEEL 

3-0. 3f2(Sr)  x  0.375"Std.  ffead/ess 

® Steel 'Screws 


\  \ 


■>M4$< 


■3.07  Maxr 
0. 06%\  y*l    *"  Case  Harden  Gaging  Surface 


Stamp:  name  ofsheff, 
gage,  dimensions  gaged, 
p/ace  of  manufacture 
and  date  (year) 


<§>^s 


MACH.  [STEEL 
Finish  q±  0.01" 


FIG.  21 


[29] 


The  rough-facing  of  the  base  is  done  in  a  drilling 
machine  fitted  with  a  special  cutter  and  holding  fixture, 
as  shown  in  Fig.  12.  The  point  of  the  case  rests  on  a 
centering  block,  and  the  body  is  held  in  a  clamping  de- 
vice. The  amount  faced  off  the  base  is  determined  by  the 
depth  of  the  cavity,  a  depth  gage  being  used  to  indicate 
this.  The  tool  head  is  fitted  with  high-speed  steel  cutters 
that  are  easily  reground  when  dull.  When  centering  the 
base,  the  inside  edge  is  first  trued  up  with  a  single  rough- 
ing tool ;  and  then  the  centering  reamer  and  counterbore 
is  run  in  as  shown  in  Figs.  3  and  16. 

Eoughing  the  point  consists  mainly  in  turning  it  to 
approximate  shape,  care  being  taken  to  get  under  the 
scale  all  around.  It  will  be  observed  that  the  case  here 
is  held  on  the  tail  center,  yet  no  mention  has  been  made 
of  the  centering  of  the  point.     This  will  be  understood 


when  it  is  explained  that  the  point  is  centered  by  the  com- 
pany that  makes  the  forgings,  in  order  to  rough  down  the 
outside  concentric  with  the  cavity.  The  body  is  roughed 
off  in  a  lathe  as  shown  in  Fig.  5,  the  point  being  held 
and  driven  by  a  special  chuck,  Fig.  19;  and  the  base  is 
held  on  a  revolving  center,  Fig.  20.  A  standard  high- 
speed turning  tool  is  used  for  the  cut. 

OPERATION  4.  ROUGH-TURN  BODY 
Transformation — Fig.  18.  Machine  Used — Le  Blond  17-in. 
lathe,  Fig.  5.  Number  of  Machines  per  Operator — Two.  Work- 
Holding  Devices — Special  drive  chuck,  Fig.  19;  revolving  plug 
center.  Tool-Holding  Devices — Tool  post.  Cutting  Tools 
— Lathe  turning  tool.  Number  of  Cuts — One.  Cut  Data — 0.040 
in.  feed,  &  to  %  in.  cut,  60  ft.  surface  speed,  70  r.p.m.  Coolant 
— None.  Average  Life  of  Tool  Between  Grindings — 15  pieces. 
Gages — Combination  snap,  Fig.  21.     Production — 200  per  8  hr. 

OPERATION    5.      FINISH-MACHINE    BASE 

Transformation — Fig.  22.     Machine  Used — Cleveland  3%  -in. 

automatic,  Fig.  6.     Number  of  Machines  per  Operator — Three. 

Work-Holding     Devices — Split     collet     chuck.        Tool-Holding 

Devices — Holder  for  combination  reamer  and  counterbore,  Fig. 


■*>\a49  f:.-Taper0.25perft 


12 
MACM.   STEEL 
f~/nish/tO.O/"Case  Harden 

FIG.  23 


Toper 0.25  per fF~> 


_^ 


Pin 
TOOL  STEEL 
finish <f±0.005"Harden 
„         „      H?6Std.  Taper  P/n 

13+0.05-- -■-->{ 

6.51-0.O5"- —  » 


SUB-OPERATION  4 


:      ■*■§     L.  ,',7'A:-U/, &»r„   7/,y/oo^/  A-l.75"for2"C/eveland     '^05% 

Y tS^~SZZL2ZZ3  0.25  Tap,50U.S.Sfd  A'2     ••  2.75     " 

*0.225"  "•■■0.25"Dri/lThreadPer,n-  „_,*,  ,-M    *-0.39' 

~  Body  0.128  Dn//~\Y  y  ^ 

I  MACM.  STEEL  O       H    036 

"J  kd/S"  fimsh/tO.OI"  025%\  U~* 

Reversing  Clutch  Spring  Cover  ReversinqClutch  Pin  Plunaer 

MACM.  STEEL       „„,;„^  t^^„  MACM.  STEEL 

finish/ ±0.01 


fACM.  STEEL        <rn~, 

ish/f 001  "Case  fJl 
Harden       ahz 


/oto.os- 


Assembled      Views 


SUB-OPERATION  5 
FIG.  22 


1 


<-l.45>\ 


10  f  0.05- 
-—7.I2S"- 


>f-2.37S-->\ 
SU,       *      ^9      \  .0.05^.0.19^^- 


gggOTTOysgas 


■4 


'0.25  Drill 


'•0.75' "Drill 
Retainer  Washer 


->j  [<-#// 


r 

Holder 

MACM.  STEEL 
fiinish/tO.Ol" 
0,5x1  "Sltt.SteelSefSowr 
FIG.  25 


fferrwe  offer 
"AssemH/ng 

Stop  Pin 


Stem 
TOOL    STEEL 
F/nish/?0.0/"Harden 

0/25"fieam-. 

§§ 

_± 

♦I  Y-0.3 
Retainer  Collar 


0.5  x/.25"Sta:  Steel  Set  Setscrew  Pivot  Point 
0/25"x  1.24" Steel  Pin^Vrjtv 


*09s: 


•»* 


\<-6Coils  -* 
l.875"rreeHt. 

Retainer  Spring 


FIG.  2-4 


OPERATION       § 


[30] 


^flfl 


r'flnfi 


i 

if  ~i!m 


idJji  iLi—jf 


TapStcf. 


Ma$x 


6ody  Bolt  Nut 
MACH.  STEEL 
FinishftO.Ol" 


■3.5" 


DrDl&CounterborefbrK  \~) 
(    )[A  Collar  Head Stcf 


Screws   , 
-2" ->\ 


Assembled      Views 


rUgb* 


OIK  -  0.003    \ 


\*<uety 

Sfd.  Threads 


SS 


...^' 


O CX-J 


Dj 


L0rillfar0.5--->(~) 


Wedge  Screw 

fih/sfiftao/' 


■o- 


^frVn^  r-r-i 

^l%\,j£il-         *   §     .-_-L-  -A  -_-  ~ 

j&\sif% s^-f-^-*-  r  Q 

Clamp 

fORGED  STEEL 
tO.  01" 
2-0.37s"x  0.625  St'd.  Head/ess  Steel  Setscretrs. 
r/ar  Po/nr 


\n\ 


~k 


0.375s 


<OM*f -2.25" '- -^0375- 


0.175 10.003  & 


x_ 


-  t  "I 


--■K-lO.STapStd: 


ittgfr  -ViTri^ti 


--H  Body        *W5**OB*-eU2»  03l2"(£)FapStd. 

EORGED  STEEL  f     /  l.75f'Deep 

-ao/         „  3-0.56Z'M)x  2.2  Std.  Collar  Head  Steel  Screws 
hQ6h  2-05V5wSfd.  Collar  Head  Steel  Screws 

H   H  0.23"t0.003 


"^T~0/25'-OOOofVa75^ 


*--ar 


FIG.  26 


Tool     Wedge 

TOOL  STEEL   _ 
Finish /tO.Ol. 


f     i 
i     i 


TT 


CO/.g-O^WV57gHJ<"-/g"">]  te 


*Q0/"  k- 


Bolt 


-325- 
■5.5"— 


3 


"    TOOL  STEEL 
-*   Finish  f 

\  &  Harden 


k'"1-95  +0.003" n 
H 25-- *1 


FIG  27  Clamping  Ring 

,  ir 

MACHINE  STEEL       P""     ' jrK"*" 

Finish f  10.01"  ->\0-875^       >]0.56Z 


w 


^■y45°    *]   |*tf2f"  § 

Finish ftQOOS','  Harden 
DRILL  ROD 
Knurl  Pin 

^:Q3l2"(§fSnug 


0.5  Tap.20Thds. 
< /.tfZS""  ■>], .per  Inch,  US.Std. 

1:                            t* 

A 

:      1                      :          • 

ae     ? 

I !  f-oK 

"a§!  t;2 

!'i  f         ;  f> 

;        ?      ± 

k- 
->1  Y-amty 


\<075^b.?SnTap,Std 
3.125" ->\         " 

■>\     \<-0.375" 


Y-:-2.062"(2if-^ 


?\PQ45'k 


a: 


II 


p-- a-   ■ 


FIS.28 

0.875"  n 
WOOL 

-0.002 

SECT/ON  A-A 


J  :.U,0.3l2ti)'keami.-  I        3 

C/?e  0.5"0.687"(£fStd  Headless  Steel  Setscrens 
»  O.Z5*Q28l"@)"  » 

TOOL  STEEL  (Pack  Harden)     Finish f  1 0.005" 
Knurl  Holder 


rQ 


WMMMSMMMML 


85>\    *  „ 


j  (12  Thds.  per  Inch,  USStH  L.H. 


0.125 


-0003 


HZ 


....  L5"......A0.6"U 5.0"- >| 

k 4.0"- >l    Stamp  name  of  projectile,  part,  size,  number  of  threads  per 

Holder  inch,  place  of  manufacture  and  date  (year)    piQ  ^9 

&&.  1  1 


TOOL  STEEL 

Finish f±0.005'i  Harden 


~n 


■7.75" 


C31 


.^10  j< 


-Q05W  '0.04- 

Stamp  name  of  shell,  place  of  manufacture  and  date  (year) 


STEEL 


0.22"  0.005- ?' 


-~fr 


:a* 


-3.5- 


-2.0" 


^L 


Z 


^7 


£ 


HIGHSPEED  STEEL 

F!nishJii—L—den 

"W*—  iifflfflHIHIlIl      IIII1I!I1P^°<vj    ti 


^-rx 


r"  h — /ayr — ->J 

HI6H-SPEED  STEEL    Finish/ 1 0.005? Harden 
OPERATION  5 


F16.31 


FIS.32 


[31] 


HIGH-SPEED  STEEL 
Finish/ ±0Ol"  Harden 


«£ 2.5"--^ 


-\0.49^---\<-QO5 


JUU 


0.375 


n 


Taper  0.25  Inch  per  Foot 
fy       (No.8Std.  Reamer) 

Stamp  name  of  shell,  place  of  manufacture  and  date  (year) 

FIG.  53 


*<£a/25 


j   Harden  Point 
U — . 

U- 


&?5/f 


-10.85" 
-11.6"-  ■ 


075 


-JL 

<--  TOOL  STEEL 
FinishpO.Ol" 


FIG. 36 


HI6H- SPEED  STEEL 

Finish/±O.OIPHarden 

Cutter 


* l6H—>f 1.8' '-■> 

0.575"TaP5td       1 1 
0.5"Deep        J  J 

1     .f 

3 

Y 

::::uz 

T 

1      P 

iaw^m 

'_       ^ 

5.4" ->U- A- 

- -  -B— - 

(25  Tap  Std.  0.75 Deep 


One  05x/.25  Square  Head  Steel  Setscrew,  Pivot  Point 
»  0.575  x0.5" Standard    »  »       Flat     >• 

Boring  Bar 


1 1.5  mi 


625*0.1 


31 


14.9  ±0.1 


9.65 ±0.1 


NAME  OF  MACHINF 


FOR  3.25  CLEV.  AUTO.  MACH.    i 
FOR  POTTER  &  JOHNSON 


MACHINE  STEEL 
Finish/ ±0.01" 


nn 


V0.15"-^"0.3**fO.I5"»f 0.2--— -A 


*35c 


0.05" 


4 


fa-' 0.06?$"^ 
SAW  STEEL 
Finish/ ±0.005" Harden 
FIG.  37 


a  £ 


., — Round-.. 


■l.l± 


Y^--0.56MaK.-—>\ 


0.25  Drill 


->\0.4 

9 


0.05"Min>  %....Q5,»Mh  ...J 


£ 


■0.25" 


£:: 


4.0  -- 

,3.25?--y* 
Y  1-75 -->^- 1.5 ->\0.75 

Q5"7apStdJ3X\<f£ 


YJs>   *t* V--S5'; 

k?75=k?75f •  -  •  3.25"n---„-A 

'l4Thds.per^%2^  Four 0.5 Holes, 


SAW  STEEL 

Finish/ ±0.005" Harden 

FIG.  38 

OPERATION  5 


■■0.57ap  Standardl:X£mcmE  STEEL     ^sh/ ±0.005 
Cap  Locknut 


mi' ,(ieJ -0.005 


U--3.25"-- 
HIGH-SPEED  STEEL  Finish/ ±0.005 
Grind  Cutting  Edge 

FIG.  35 


,  One  Q5*/.I25  Std  Steel  Setscrew 
J  -  0.5*1375"  »      » 
"  0.375x1.0"  »      » 
Two  0.5"  1.125" Std  Filisterhead  Screws 


^■25"-H 

[Snug 


*-J9-* 


3 


10"*  , 
HIGHSPEED  STEEL(Harder) 

FinishftO.Ol" 
Bourrefet  Cutter 


,  Plate  ,         r V75* 

/mCHSTEEL/inisr/ta0f025,-->\  U—  — JI25" 

0.51  f§ mi5"dtandard  Counter]  L77*/7)» 

sunk  Head  Steel  Screws  I  ^'.m*^" *75"- :*; 

03l2"(gx0.3"StandardCounter]t^-'Y-^---^" 

|  |   Q     \    Q  0.5"Tap  Q 


—.^W'S  h" 


-40/-  »-^W 

HIGH-SPEED  STEEL(Harden) 
FinisHjCtO.Ol" 
Ogive  Cutter 


FIG.  47 


Body 

AM0¥.  STE£L,Flnish/taOl" 
0.5"U81S"Standard Steel  Setscrews 
0.625"X!6255'Standard  Steel  Setscrews 
02,15'KZ  75"Steel  Dowel  Pins,  Drive 


Hi    iH^.H 


'J[0p3t' 0.937"  \ 
\-1.875"—A 


c 


*0-0l--4.75"- J 


-475" 
-4.875" 


1 


0.3/2%pStd 
06" Deep  \ 


3    :;i 

Mi 


ii  0525  Wi 


Drill  tor 
'0.625"Bolt 


^c=± 


llr^J 


■0.125"  \ 

Securing  Bolts 

COLD-DRAWN  STEEL 

Finish/to.0l" 

0.625"Nuts 


-—Block 
1    MACH.STEEL/inish/t  O.Ci" 


OPERATION  6 


[32] 


Stamp  Name  of  Shell,  Gage,  Dimensions 
gaged.  Place  of  Manufacture  and  Date  (Year) 

<- 5.75'- ■ 

i*""" """""""""-II*' Engrave  Lines 

J>  >^^~    0.005' wide 

&  %o   f^Jj.005" deep\ 

_t y  i^tt 

L-  1.08' >«■■  l.l6"d<-/2-"-^-/,2'-l\ 
[Straight'       i  +\<«0.Q3" 

■* 4™4& 3|    ' 

H 3.984'-- >| 

L  SAW  St  EEL  (Harden) 

Finishjr+O.Ol" 
FIG.  48 


'  Stamp  Name  of  Shell;  Part,  6age,  Dimensions 
^daged,  Place  of  Manufacture  and  Date(Year) 


0.5 


PIG.  49 
OPERATION  6 


-^cr -2.99  Max:—- ■ •-> 

0.06"-AV\ 

'Case  harden  gagingSurfaces 
MACHINE  StEELfinish  g+O.Oi' 
FIG.  50 


Ogive  Cutter  Slide 

MACHINE  fEELfinishf+QOl" 
0.431%)  U6Z5" Standard 
Headless  Steel  Screws 


FIG.  45 


0M$$)TapSfd-@ 


1375  >W.25"*U- 1.875- 
+0.000" . 
-0.002" 


Vff, 


+aoo. 

'0.01' 


Of' 


usr- 

Snug 
•Bourrelet  Cutter 

WW  SPEED  STEELlHardenL.-, 
Finish  ft  doi'       /Q2S-..h 


O.I&U~l.87S"- 
\<-20Z5 


3. 

Bourrelet  Cutter  Slide 

MACHINE  STEEL,  Finish ft O.Ol" 
0.457%)  X.1.625"  Standard 


headless  Steel  Screw 


0375' 


mmd-drwnsteclV 

FinishftaOl" 
I    <-J  <-J  UJ         j  0.625'Nuts 

WIS-  t<-—t'—.  ->!<-— 2--  - ■  ■-b.-l.ZS'A  08Z5"  Washers 

-,6"- --->!    ,*rf^%^- 


'O.OtXf 

*o.ooz*-' 

C375"-> 


* 


Jg{ 


\4l5i<WE5' ^^<-l.875"-^ 
<Q875$<-l.5"---'\<-—22S~-^<-l375"<\ 


.1 


Body 

MACHINE  STEELfinishftQOI* 
'  0.5'xi.875"Standard  Sfeel  Setscrews 

FIG.  46 
OPERATION  6 


0.875  U~  .  Ao.6"\* 
+0.00" 


Ogive  Cutter 

HIGH-SPEED  STEEL,  (Harden) 
'Finish ft  0.01" 


-0.01* 


23;  tap  holder,  Fig-.  24;  tap-holder  adapter,  Fig.  25;  cutoff  tool- 
holder,  Fig.  26;  form  tool  holder,  Fig.  27;  knurl  holder,  Fig.  28. 
Cutting  Tools — Tap,  Fig.  29;  cutoff  tool,  Fig.  30;  form  tool  for 
band  seat  and  groove.  Fig.  31;  knurl,  Fig.  32;  counterbore,  Fig. 
33;  boring  tool,  Fig.  34;  facing  tool,  Fig.  35.  Cut  Data — 80  r.p.m. 
Coolant — Zurn  cutting  oil,  %-in.  diameter  stream.  Average 
Life  of  Tool  Between  Grindings — Tap,  3  or  4  days;  forming 
tool,  1  day;  reamer,  3  or  4  days;  cutoff,  J  day;  other  tools,  2  days. 
Special  Fixtures — Stop  in  pusher  tube;  pusher  stop,  Fig.  36. 
Gages — Depth  of  cavity,  Fig.  14;  position  of  band  and  grooves, 
Fig.  37;  band-seat  width  and  depth,  Fig.  38;  maximum  ring, 
rear  of  band,  Fig.  39;  minimum  ring,  rear  of  band,  Fig.  39; 
diameter  and  depth  of  fuse-flange  seat,  Fig.  40;  maximum 
thread  plug,  Fig.  41;  minimum  diameter  of  thread  and  eccen- 
tric of  counterbore,  Fig.  42;  combination  snap-band  seat,  Fig. 
43;  position  and  width  of  band  seat,  Fig.  44.  Production — 32 
per  8  hr.  per  machine. 

OPERATION  6.  FINISH.  POINT 
Transformation — Fig.  45.  Machine  Used — Cleveland  3*4 -in- 
automatic,  Fig.  7.  Number  of  Machines  per  Operator — Two. 
Work-Holding  Devices — Split  chuck.  Tool-Holding  Devices — ■ 
Roughing  toolholder,  Fig.  46;  finishing  toolholder,  Fig.  47. 
Cutting  Tools — Tool  for  roughing  ogive,  Fig.  46;  tool  for 
roughing  bourrelet,  Fig.  46;  tool  for  finishing  ogive,  Fig.  47; 
tool  for  finishing  bourrelet,  Fig.  47.  Number  of  Cuts — Two, 
roughing   and    finishing.      Cut    Data — 50    ft.    surface    speed,    57 


r.p.m.  Coolant — Zurn  cutting  oil.  Average  Life  of  Tool 
Between  Grindings — 60  pieces.  Special  Fixtures — Pusher  stop; 
spring  stop.  Gages — Profile,  Fig.  48;  maximum  diameter  of 
bourrelet  ring,  Fig.  49;  minimum  diameter  of  bourrelet  ring, 
Fig.  49;  combination. snap  bourrelet  diameter,  Fig.  50.  Pro- 
duction— 64  per  8  hr.  per  machine.    ; 

OPERATION  7.  FINISH-TURN  BODY 
Transformation — Fig.  51.  Machine  Used — Reed  18-in.  Jathe, 
Fig.  8.  Number  of  Operators  per  Machine — One.  Work-Hold- 
ing Devices — Universal  three-jaw  chuck,  with  extension  jaws. 
Cutting  Tools — Lathe  turning  tool.  Number  of  Cuts — One. 
Cut  Data — 125  ft.  surface  speed;  150  r.p.m.;  0.045  in.  depth  of 
cut;  0.024  In.  feed;  total  length  of  cut,  5Y2  in.  Coolant — None. 
Average  Life  of  Tool  Between  Grindings — 20  pieces.  Special 
Fixtures — Revolving  center;  center  plug  in  spindle.  Gages — 
Combination  snap-body  diameter,  Fig.  52.  Production — 200 
per  8  hr. 

OPERATION  8.  NOTCH  BASE 
Transformation — Fig.  53.  Machine  Used — Brown  &  Sharpe 
hand  miller,  Fig.  9.  Number  of  Operators  per  Machine — OneJ 
Work-Holding  Devices — Fixture,  Fig.  54.  Tool-Holding  De-j 
vices — Arbor.  Cutting  Tools — Cutter,  standard  60  deg.,  2.75 
in.  in  diameter,  0.5  in.  thick,  22  teeth.  Number  of  Cuts — Three. 
Cut  Data — Cutter  runs  370  r.p.m.  Coolant — None.  Gages — 
None.     Production — 600  per  8  hr. 


[33] 


d.l5ft02"Standard  k 
Countersunk  Head    > 
f  BronzeScrews  . 


Z8'—->\  Name  p|at 


Automatic  machines  like  the  one  in  Fig.  6  are  used  to 
finish-machine  the  base.  The  interior  is  rough-bored, 
eounterbored,  tapped  and  the  end  faced.     While  these 


operations  are  going  on,  the  form  tool  for  the  band  seat 
does  its  work,  and  the  bottom  of  the  groove  is  knurled 
with   a  knurling  tool  carried  in  the  front  tool  block. 


1                                                                        f   ■          , ; i^ 

-•r;<C^!if 

— --^I       -..            -                    -      ':;. jr"L.aC»ssi_ \     f*    f                               '                                ■! 

FIG.  58.     ROUGHING  BASE-COVER  GROOVE 


PIG.  59.     FINISHING  BASE -COVER  GROOVE 


[34] 


,<~.3-->, 


MACHINE  STEEL 
Finish f  ±0.01"  Case  Harden 

O.I25nDrill 
r*0.S-M 


■6.0 


O.I8?\\< 


„  .-.0.1  MACHINE  STEEL     QZ5^A^ 

■Q05R.      rfj.U    Finish  (±0.01" Case  Harden   ?       <£ 


FIG.55 


■0625 


•H0.5K  _k--/2-*t    a/25*  H-  Flfi  e7T  ,     /r 

Cross  Bor 


7T> 
OPERATION  9 


Rod 


O.I25"Drill 


Uo.5U 


Stamp  name  of  shell,  part,  operation- 
place  of  manufacture 

and  date  (year)  0.3% 


kbk4'For  a575*l25"$td 

■•1*1      1     Square  Head 

Steel  Setscrew 


-&- 


!\.    (t  A 


W- 


0.675 


0375  TapStd. 
^■-y  0.39  ±0.005 


3.4371 


J   7 


X~ 


L.A 


■7.125- - H  /.tf"K 4.625"-"' J        '  -HBK5J5- 

l2J5"i0.03"- HF0R6ED  STEEL 

PIS.56  Finishf±O.Ol" 


-2.5" 


Gfc 


-2Z5  /%».- 


5A7/77/3  name  of  projectile, 
gage,  dimensions  gaged, 
place  of  manufacture 
and  date  (year) 


TO 


Q062'($\r 


fg 


HQ35 


i. 


Taper  Q562*(§}" 
Inch  per  Foot  f 

k ft- 


FIS.64 


_  _ - E^  - 

«  g.1—1  I         W  f  025"- 


<20£Hh 22* ///>». >i    Finish f  ±0.01  Harden 

£16.66  rf. 

„       0.25"Square  x  0.5* *  Steel  Key 
0.05  R.--     Force  in  Holder,  snug  in  Cutter 


Holder 

MACHINE 

STEEL 
Fimsh/m 


-0,002 


H    V-0.35' 


k ^ 

--595"- - 


OPERATION  IO 


fl2J  fcfl£j.fl52l 

Cutter 

"*1  HIGH-SPEED  STEEL 

Finish/ ±001"  Harden 
v (Taper  Shank(shown  in  full)  for  Engine  Lathe 
\  Straight  Shankfshom  in  dot  and  dash)  for  hand  Screw  Machine 


WW 

Drill 

Tap  for  03l2r(i)xQ75"Std: 
Hex.  Head  Steel  Screw 


FI6.65 


OPERATION  9.  BORE  INTERIOR 
Transformation — Fig.  55.  Machine  Used — Reed  18-in.  lathe, 
Pig.  10.  Number  of  Operators  per  Machine — One.  Work- 
Holding  Devices — Universal  10-in.  three-jaw  chuck;  steady- 
rest.  Tool-Holding  Devices — Toolholder,  boring  bar,  Pig.  56. 
Cutting  Tools — Cutter  for  boring  bar.  Cut  Data — 150  r.p.m. 
Coolant — None.  Average  Life  of  Tool  Between  Grindings — 
30  pieces.  Gages — Maximum  and  minimum  length  of  thread, 
Fig.  57.     Production — 160  per  8  hr. 


OPERATION  10.  ROUGH  BASE-COVER  GROOVE 
Transformation — Fig.  64.  Machine  Used — Bardons  &  Oliver 
turret  lathe,  Fig.  58.  Number  of  Operators  per  Machine — One. 
Work-Holding  Devices — Set  collet  pads,  3  in.  in  diameter. 
Tool-Holding  Devices — Holder  for  cutter.  Cutting  Tools — - 
Circular  roughing  cutter,  Fig.  65.  Cut  Data — 115  r.p.m.,  50  ft. 
cutting  surface  speed.  Coolant — None.  Average  Life  of  Tool 
Between  Grindings — 60  pieces.  Gages — Diameter  of  groove, 
Fig.  66.     Production — 240  per  8  hr. 


PIG.   60.      BAND-ASSEMBLING  GROUP 


FIG.  61.     SPECIAL  BAND-TURNING  MACHINE 


FIG.  62.     TURNING  BANDS  IN  A  LATHE 


FIG.  63.    RESIZING  THREADS  AND  COUNTERBORE 


[35] 


^04^-0.7^04% 


G 


■•*,■ 


-->J 
->K-- 


Stamp:name  of  shell,  name  of  holder^ 
and  machine,  place  ofmanufacture 
ana  date  (year) 

*" A 


-pQZ/S^Max. 


9961?.. 


•5.5- 


■*3"ft 


„MACJ1.i  STEEL .  finish  ft 0.0/ 
4025x0.75  Std.  Steel Sefscretvs f/at/rm 


FIG.  68 


KflJ-H 


"1/7 
Inside     Tool 
HIGHSPEED  STEEL 

FIG.  69 


&4£ 

->J    V9°S' 
Outside    Tool 


-0.062"(IJ 


cr~*r 


Stamp: name  of  pro/ec-  N 
tiles,  gage, dimensions  ! 
gaged,  place  ofmanufac-  \ 
tune  and  date  (year) 


i     tj 


/<? 


>1 


HIGH-SPEED   STEEL 
FIG.  70 

OPERATION 


,-J    B   0/55Min. 

M0.I9$<  Mia 
SAW  steel  /7mshfr0.0l"tiarden 
FIG.7I 


From  this  machine  the  cases  go  to  an  automatic,  Fig. 

7,  where  the  point  and  the  bourrelet  are  roughed  and 
finished  with  similar  tools  carried  in  tool  blocks  on  oppo- 
site ends  of  the  same  cross-slide. 

In  finish-turning  the  body,  it  is  held  in  a  lathe  just 
the  reverse  of  that  in  the  rough-turning,  as  shown  in  Fig. 

8.  The  point  rests  in  a  centering  plug  in  the  spindle, 
and  the  base  is  held  in  a  special  revolving  center. 

The  base-notching  fixture  is  shown  in  Fig.  9.    The  shell 
is  held  in  a  collar  into  which  it  is  locked  by  means  of  a 


setscrew.  The  outer  end  is  supported  by  two  rollers. 
As  the  cutter  runs,  the  operator  works  the  feed  lever  with 
one  hand  and  indexes  the  shell  with  the  other.  These 
notches  are  cut  so  that  the  fuse  can  be  locked  in  place 
after  it  is  screwed  home. 

For  the  purpose  of  boring  the  interior  the  shell  is 
chucked  base  out  in  a  universal  three-jawed  chuck,  with 
the  outer  end  in  a  steadyrest,  as  shown  in  Fig.  10.  A 
strip  of  tin  is  wrapped  around  the  shell  where  the  chuck 
jaws  grip,  in  order  to  give  them  a  better  hold  and  not  mar 


If 


I.37S  Countertxre 
Surface 


.     4-CASTSTFFL 

•■*      tO.05" 


)A-303fbr295Projectile  A-3.1  for  3  Projectile 
/■A-3.9"°   3.6?       »        A^.32'-47      » 
— ■"■    A-6.14'-  6"        <■ 
FIO.  74 

----- 48.0'tai- 

\_J  .1.25' 


T  r 


four  0.625*175  Belts  and  Nuts 
>^5" ■  KXT-  ■"oM\ 


)rllTfo?Q625*Bolts^ 
\*25->*+Z!rA 


.   iMiii 

*S  0.5 1  k 
J 


C0LD- DRAWN  STEEL 
Finish/ tQ0l' Two  0515'Nuts 

Punch  Bolt  .tt^q 


SECTION  A-B-C 

Tap  for  Six  0.25" Q75"  Qtf 

Cskhead  Steel  Screws,  "vr 

1437"  <£Wj?7,{     fj 


Jq>3375*<W/|<-  FmishpO.002 
f?  AUX'QQOl'i?        Marden 

r*h*®L     T00L 

*  1.875  *  ft  ^Q  STEEL 


!K£ 


■so"    #r 

'Too  Std.    g? 
0.625*Deep   ^ 
75"---.HG1S7  §WStd.Thd  ^ 

nnrf ':.-.' IRON.      '  ■*wfl«*K;i,      '& 

■oo°H  \&  itsbSH 


0.375  Drill- 
JiV  -0.375".^ 

BRASS   Finish fWI  0.25*^ 
Guide 


Bushing 

'Wtf$Drill 

" "  m" 


si—S) 


45 ^iy^.Q.575 


K 6.75 >< 

MACHINE  STEEL  Finish  J  tO.OI 


(    -0.875" 

t 


0.625  Std.  Thd-.. 


Strap 


0375  Drill- 

„^0.6"Rr 
02\^r^MA3f(if 

-^  J'ilPl  "I  T00L 
Ql"-+^$  ^  STEEL 

^Approx*  a6 
Finish ft  0.002"  Harden 

Punch 


COLD-DRAWN  STEEL 
FinishJtQOr 
\  Four  0.3121$)' "Nuts 
Connecting  Bolt 


0.032 

Subject  to    *■  55  Appro*, --*\ 
Experiment       !2Coils       0.5 
STEEL  MUSIC  WIRE  (W.Ol)" 
Spring 


0.375r 


.  -H  H-<25 


&o. >te« 

8.75  A 

COLD-DRAWN  STEEL 
Finish  tOOl" 
'  Handle 

FIG.  73 


Q655td.M 

y 


0675 


°Sd.    ^0.25"hl25- 

COLD- DRAWN  STEEL  . 

Finish J 't'QOl"  Two  Q3l2ti) Nuts 

Pivot  Stud 


□  : 


0494 


0375  STD.  STEEL 

PIPE 
Distance  Piece 


Tap.5td:'  ltf$\- 0.8/5 
TOOL  STEEL 
Finish  ft  0.002" Harden 

Cam 


4t0' 


OPERATION  \Z 


[36] 


the  work.  The  boring  bar  is  of  the  ordinary  type  with  a 
single-point  cutter.  The  inside  of  the  shell  is  trued  up 
for  about  3  in.  from  the  outer  end,  and  the  length  of 
thread  shoulder  is  machined  back  from  the  inside  to  the 
required  distance. 

The  base-cover  groove  is  first  roughed  out  with  a  cir- 
cular cutter,  Fig.   58,  the  shell  being  held  in  a  collet 


-6.35" 


II 


,:I0° 


$  <sV:>    -0.002 


t 


\3?° 


aofmooz" 


-&- 


HIGHSPEED  STEEL  (Finish  f±O.0l",  Harden) 
FIG.60 


35° 


JptiftpSi 


ao5"±aoo5" 


5S*I 

HIGHSPEED  STEEL  (Finish  f  ±001",  Harden) 
FIG.  81 
OPERATION  13a 

chuck.  From  this  machine  the  shell  goes  to  the  one 
shown  in  Fig.  59,  where  the  groove  is  dovetailed  and 
finished  to  correct  dimensions. 

The  work  on  the  copper  rotating  bands  is  the  same  on 
both  the  common  and  the  shrapnel  shells.  The  outfit  used 
in  assembling  the  bands  to  the  shell  case  is  shown  in  Fig. 


60.  The  bands  are  placed  in  the  furnace  at  the  left  by 
means  of  a  long  rod,  about  a  dozen  or  more  being  handled 
at  a  time.  The  bands  are  heated  to  a  low  red  heat;  then 
one  is  seized  with  a  pair  of  tongs  and  placed  in  a  locating 
fixture  in  the  arbor  press.  A  shell  is  then  set  in  and 
pressed  down  until  the  band  is  on  a  line  with  the  groove. 
It  is  lightly  pressed  in  and  passed  to  the  hydraulic  band- 
ing press,  where  the  band  is  forced  securely  into  .  the 
groove. 

OPERATION    11.      FINISH   BASE-COVER   GROOVE 
Transformation — Fig.     67.       Machine    Used — Flather    16-in. 
lathe,    Fig.     59.       Number    of    Operators    per    Machine — One. 
Work-Holding  Devices — Universal   lathe  chuck,   9   in.;   steady- 
rest.      Tool-Holding   Devices — Tool   holder.   Fig.    68;   tool   post. 
Cutting  tools — Inside  tool,  Fig.   69;   outside  tool,  Fig.   70.     Cut 
Data — 150   r.p.m.     Gages — Diameter   of  groove,   Fig.    66;   depth 
and  width  of  groove,  Fig.  71.     Production — 160  per  8  hr. 
OPERATION   12.     ASSEMBLE  BAND 
Transformation — Fig.    72.      Machine    Used — Banding    press, 
furnace  arbor  press,  Fig.  60.     Number  of  Operators  per  Opera- 
tion— Two.      Pressure    Required — 1300    lb.      Special    Fixtures — ■ 
Fixture  to  locate  band  in  groove,  Fig.  73;  set  of  banding  dies, 
Fig.  74;  tongs,  Fig.  75;  bar  for  bands.     Gages — None.     Produc- 
tion— 150   per  hr.      Note — First   operator   puts  about   40   bands 
on  a  bar  and   inserts  in  furnace;   when  the   bands  are   at  red 
heat,    the  operator   takes   one   out   with   tongs   and   drops   into 
arbor-press  fixture,  then  drops  in  shell  butt  first,  slightly  com- 
presses  band   and   passes   shell   to   man   at   banding   machine, 
who  finishes  the  operation. 

OPERATION  13.  TURN  BAND  ON  LATHE 
Transformation — Fig.  76.  Machine  Used — Reed  18-in.  lathe, 
Fig.  62.  Number  of  Operators  per  Machine — One.  Work- 
Holding  Devices — Universal  9-in.  three-jaw  chuck.  Tool- 
Holding  Devices — Two  tool  posts.  Cutting  Tools — Standard 
band-turning  tool;  standard  band-facing  tool;  10-in.  mill  file. 
Number  of  Cuts — Two,  forming  and  facing.  Cut  Data — 330 
r.p.m.,  320  ft.  surface  speed.  Average  Life  of  Tool  Between 
Grindings — About  y2  day.  Special  Fixtures — Revolving  cen- 
ter; form,  Fig.  77;  form  holder,  Fig.  77;  form  follower,  Fig.  77. 
Gages — Band  profile,  Fig.  78;  maximum  diameter  of  band  ring, 
Fig.  79;  minimum  diameter  of  band  ring,  Fig.  79.  Production 
— 400  per  8  hr.  Note — Band  is  profile  turned,  faced,  and  then 
smoothed  with  file. 

OPERATION  13-A.  TURN  BAND  ON  SPECIAL  MACHINE 
Transformation — Fig.  76.  Machine  Used — Fig.  61.  Number 
of  Machines  per  Operator — One.  Cutting  Tools — Roughing 
tool,  Fig.  81;  finishing  tool,  Fig.  80;  end  scraper  for  hand  use 
on  rest.  Number  of  Cuts — Two.  Cut  Data — Spindle  runs  145 
r.p.m.;  120  ft.  per  min.  surface  speed.  Special  Fixtures — Out- 
side swing  bracket  is  a  stop;  front  swing  bracket  is  hand- 
scraper  support.  Gages — Same  as  operation  13.  Production — 
750  per  8  hr. 


fifi: 


Ttogwrncr 

—  3- ->]■  Q3IE(§)TapStd 


FIG.  76 


--->]<■- -0.56-">\ 


r       T00LSTEEL  0.06Z%JR. 'I       ..J.pxa'. 

(Harden)  Finish/±0.005" 


[  J  j        /      'End     ; 


\J 


TX 


__¥ 


One  A  =0.05' '(For5 Inch  Com. Shrapnel) 
One  K-0.04  (For 295 Inch  Shrapnel) 
Form      „ 


TOOL  STEEL, 
->\FinishJ±Q005 


MACHINE 'STEEL  FinishJ±0.005 
0.3l2"(j§)X0.75"5ta,Filisterhead  Steel  Screws 

Q93f($H 


k?5i 


-f—T 

'      *  i 


toi 


ForQ3IE"(gfFilisterheadJ 

Standard  Screw      '  ,Mcm£,  STEEL.Finishf  10.01' 

&?£  (%)XZ5"StandardFilisterhead  Steel  Screw 
Holder 


FI6.77 


^MHCHINE  STEEL 
FinishJ±Q005' 

0.5"Nuts 
Tie  Bolt 
OPERATION   13 


V 


*_ 


2 


Max.  Height 
of  Profile 


# 


*Q25'Drill 


Min.  Height 
of  Profile 


EngraveLines 
,  0.005' Wide 
0.005'Deep 

<Q3/U    >Jk    " 


-<QQ2" 


<—-0£"—-^.---0£6-- 

SRW  STEEL,  (Harden)  Finish  j  t  Q  0? 
FIG.7Q 


i_U 


(h)ao6& 


0.5 


FIG.79 


[37] 


FIG.82.0RI4 


FIG.89,  OR  15 


Q75"Rad.     if":  \/o"  - 

5  "n*U#  *"RF 


Upper  Ring 


FORGED  STEEL        FINISH  ft  0.01^ 
Punch  • 


OPERATION  14.  RESIZE  THREADS  AND  COUNTERBORE 
Transformation  —  Fig.  82.  Machine  Used  —  Warner  & 
Swasey  turret  lathe,  Pig.  63.  Number  of  Operators  per 
Machine — One.  Work-Holding  Devices — Pot  chuck;  steady- 
rest.  Cutting  Tools — Boring  tool;  counterbore;  tap.  Cut  Data 
■ — 80  r.p.m.  Coolant — Lubricated  with  lard  oil  put  on  with 
small  brush.  Gages — Thread  gage  and  counterbore.  Produc- 
tion— 280  per  8  hr.  Note — The  shells  are  now  inspected  all 
over  and  divided  into  three  weight  classes:  12  lb.  1  oz.  to  12  lb. 
4  oz.,  12  lb.  4  oz.  to  12  lb.  8  oz.,  and  12  lb.  8  oz.  to  12  lb.  12  oz.; 
these  weights  are  then  averaged  in  the  loading  process. 


OPERATION  15.  SANDBLAST 
Transformation — Fig.  89.  Number  of  Operators — One. 
Description  of  Operation — The  operator  lays  a  row  of  shells 
on  the  special  bench,  Fig.  83,  with  open  ends  out,  pulls  the 
hinged  cover  nearly  down  and  thrusts  the  end  of  sandblast 
nozzle  into  hole  in  shell,  sandblasting  the  interior  to  remove 
scale.  Apparatus  and  Equipment  Used — Paxson-Warren  sand- 
blast equipment,  using  No.  5%  chilled-steel  shot,  made  by 
Globe  Steel  Co.,  Mansfield,  Ohio;  80  lb.  air  pressure,  with  %-in. 
diameter  nozzle  outlet.  Gages — None.  Production — 3000  per 
8  hr. 


FIG.  83.     SANDBLASTING  APPARATUS 


FIG.   84.     PRESS  FITTED  FOR  HYDRAULIC  TESTING 


[38]' 


pi 


OPERATION  16.  HYDRAULIC  TEST 
Description  of  Operation — Case  is  placed  in  a  vise,  and  a 
_ug  is  screwed  into  the  end  to  make  it  water-tight;  the  case 
is  then  placed  in  a  special  fixture,  Figs.  84  and  90,  in  a  1500- 
ton  heading  press;  the  pressure  applied  is  350  tons,  or  20,000 
lb.,  per  sq.in.  Apparatus  and  Equipment  Used — 1500-ton  head- 
ing press;  pressure  pump;  testing  fixture,  Fig.  90;  triplex 
chain  drop;  common  vise.     Gages — None. 

OPERATION  1.  PAINTING  INTERIOR  BY  HAND 
Transformation — Fig.  91.  Number  of  Operators — Two. 
Description  of  Operation — Operator  pours  case  full  of  Cebal- 
ine  anti-acid  paint  up  to  threads,  then  pours  it  out  and  sets 
case  in  rack,  base  down,  to  drain  a  minute  or  so;  second  oper- 
ator takes  a  drained  case  from  rack  and  wipes  end  and 
threads  with  waste,  and  places  it  in  truck  box  to  dry;  paint 
dries  rapidly  in  about  1  hr.  Apparatus  and  Equipment  Used 
— Cans  of  paint,  pans,  draining  rack,  waste,  Fig.  92.  Produc- 
tion— 1200  per  8  hr. 

OPERATION  1-A.  PAINTING  INTERIOR  WITH  A  SPRAY 
Transformation — Fig.  91.  Number  of  Operators — One. 
Description  of  Operation — Using  the  spraying  apparatus,  Fig. 
85,  the  operator  thrusts  the  nozzle  inside  a  shell,  presses  the 
valve  lever  and  sprays  the  inside  to  the  threads;  he  then 
shuts  the  valve  and  withdraws  nozzle.  Apparatus  and 
Equipment  Used — Eureka  spray  and  Cebaline  anti-acid  paint. 
Production — 10  per  min. 


OPERATION  2.  WEIGHING 
Number  of  Operators — One.  Description  of  Operation — 
Operator  places  case  on  scale  platform,  weighs  it  and  chalks 
weight  on  side,  Fig.  93,  then  places  piece  in  tote  box,  ready 
for  elevating  truck.  Apparatus  and  Equipment  Used — Small 
platform  scale.     Production — 1600  per  day. 

OPERATION  3-A.  FILLING  WITH  TRINITROTOLUOL 
Transformation — Fig.  94.  Number  of  Operators — Three  in 
gang  for  filling  and  compressing.  Description  of  Operation — 
A  complete  fuse  and  base  cover  are  kept  on  platform  of  scale; 
first  operator  weighs  out  enough  trinitrotoluol  in  a  tin  con- 
tainer to  bring  total  weight  of  case,  fuse  and  base  cover  to 
15  lb.;  he  then  pours  the  trinitrotoluol  into  case  on  holding 


FIG.   85-     INTERIOR  PAINT-SPRAYING  OUTFIT 


FIG.  86.     FILLING  WITH  TRINITROTOLUOL 


F£G.    87.      COMPRESSING  THE   TRINITROTOLUOL 


FIG.    88.     HOLDING  FIXTURE  AND  RAMMER 


[39] 


block  and  rams  down  powder  with  brass  rammer  and  heavy 
rawhide  hammer;  load  is  then  compressed  in  hydraulic  press; 
in  case  of  a  light-weight  shell,  more  powder  is  added  and 
again  compressed,  in  some  cases  several  compressions  being 
necessary  to  get  enough  powder  in  to  bring  weight  high 
enough.  Apparatus  and  Equipment  Used — Small  platform 
scale,  rawhide  hammers,  brass  rammer,  holding  blocks,  Fig. 
86.     Production — 320  per  day. 

OPERATION    3-B.      COMPRESSING    THE    TRINITROTOLUOL 

Transformation — Fig.   95.     Machine   Used — Riehle   40,000-lb. 

hydraulic     press.       Number     of     Operators     in     Gang — Three. 

Punches  and  Punch'  Holders — Bronze  ramming  punch,  Fig.  96. 


OPERATION  4.      REAMING  FOR  FUSE  CASE 
Transformations — Figs.  103  and  104.     Machine  Used — Small 
lathe.  Fig.  97.     Number  of  Machines  per  Operator — One.     Cut- 
ting Tools — Reamer,   Fig.   105.     Gages — Stop  collar  on   reamer. 
Production — 1200  per  8  hr. 

OPERATION  5.  CLEANING  THREADS  AND  COUNTERBORE 
Number  of  Operators-1— One.  Description  of  Operation — 
Operator  places  case  on  revolving  fixture,  Fig.  98;  cleans 
threads  and  counterbore  with  hook  tool  and  scraper;  then 
wipes  with  waste  soaked  in  benzol  and  finally  wipes  with  dry 
waste.  Apparatus  and  Equipment  Used — Fixture,  Fig.  107. 
Production — 350  per  8-hr.  day. 


FIG.  97.     REAMING  FOR  FUSE  CASE 


FIG.  98.     CLEANING  THE  THREADS 


FIG.    99.     PAINTING   THE   OUTSIDE 


FIG.   100.     PUTTING  IN  FUSE  AND  BASE   COVER 


FIG.   101.     PRESSING  ON  BASE   COVER  WITH  TRACER 


FIG.  102.     PLANISHING  THE  BANDS 


Description  of  Operation — Second  operator  takes  filled  case 
and  puts  in  hydraulic  press;  third  operator  then  operates 
valve  levers  from  outside  of  "bombproof,"  as  soon  as  second 
operator  is  outside,  and  watches  operation  of  press  ram  from 
a  mirror  placed  as  shown  in  Fig.  87;  about  30  sec.  is  required 
for  ram  stroke  each  way;  the  punch  is  forced  in  4%  in.  from 
end  of  case,  which  is  4%  in.  +  y8-in.  allowance  for  end  of 
detonator  fuse.  Pressure  Required — Pressure  varies  according 
to  amount  of  trinitrotoluol  needed  to  bring  weight  of  case  to 
15  lb.  ±2%  oz. ;  on  cases  weighing  12  lb.  2  oz.,  about  24,000 
lb.  pressure  is  required;  from  12  lb.  4  oz.  to  12  lb.  6  oz.,  14,000 
lb.;  12  lb.  14  oz.,  8000  lb.;  as  a  rule,  12-lb.  2-oz.  cases  are 
considered  too  light,  as  the  pressure  required  to  force  in 
enough  trinitrotoluol  makes  the  work  too  dangerous.  Special 
Fixtures— Case-holding  fixture,  Fig.  88.  Production — 320  per 
day.  Note — The  bombproofs  in  which  the  presses  are  placed 
are  of  concrete  about  7  ft.  wide,  9  ft.  long,  10  ft.  high,  with 
walls  1  ft.  thick. 


OPERATION  6.  PAINTING  OUTSIDE 
Transformation — Fig.  108.  Number  of  Operators — One. 
Description  of  Operation — Operator  chucks  case  in  small  lathe. 
Fig.  99,  fitted  with  split  centering  chuck,  pushing  butt  end 
in  as  far  as  the  rotating  band  will  allow;  he  then  starts  lathe, 
which  runs  240  r.p.m.,  and  applies  paint  with  wide  brushes. 
Apparatus  and  Equipment  Used — Black,  red  and  gray  paint; 
three  brushes  to  suit.     Production — 350  per  day. 

OPERATION  7 -A.  PUTTING  IN  FUSE  (WITHOUT 
NIGHT  TRACER) 
Transformation — Fig.  109.  Number  of  Operators — One. 
Description  of  Operation — Operator  puts  case  in  vise  and  sees 
that  reamed  cavity  is  clean  and  deep  enough;  if  not,  he  puts 
in  a  reamer  and  pounds  and  rotates  it  until  of  the  desired 
size;  if  the  threads  are  tight,  he  retaps  them;  the  threads 
of  the   detonating  fuse  are  greased  with   cosmoline,   and   it   is 


[40] 


|*/3?>t<--2.45-''->f«/">| 


FIG.  103 


Afotefw    0/87*1  HIT.    ->i;N3V--245 -*1T  "I0*7-* 
No.4Morse.$       H-(— — kU_.  . 

ro^rP/>7_jlxi-H^  -  -  T  TrV-rxi ■ JJ — J  —, 

=1 


4Cuts0.62S"x 
0.575"  Collar 


No3  Morsel  T^T 


t 


••25-' 


-><l*2Ce?fe£l<- 4.75"--- ■ 


4  Blades*     S 


v *^_ ^  STEELfHaraen A  finish) 


I     per  Inch 


OPERATION  4 


Reamer  with  Stop 
(For  Medium  Caliber  Base-detonating  Fuse) 
v         FIG.  105 


screwed  home  with  a  long  spanner  wrench,  then  locked  In 
place  by  means  of  a  punch  used  at  the  three  milled  notches 
in  the  case;  the  spanner  holes  are  filled  by  pounding-  in  lead 
slugs,  Fig.  110;  lead  disk  and  base  cover  are  put  on;  lead 
calking  washer  is  put  in  base-cover  groove  and  pounded  down 
all  around,  securely  holding  base  cover  in  place,  Fig.  111. 
Apparatus  and  Equipment  Used — Common  vise,  reamer,  bronze 
hammer,  tap,  spanner  wrench,  cosmoline,  complete  detonator 
fuse,  base  cover,  lead  ring,  boxes  of  lead  slugs,  Fig.  100.  Pro- 
duction— 160  per  day. 


FIG.  106 


Base  of  Shell  Before  and  after 
Caulking  Wire  is  hammered  down 

Dimensions  of ' Disk,Cmer and  Caulking  Wire 
imch Shell-  A*£25",  B'O.Ol'and C=76? 
FIG.  109 


for 


Sy'        OPERATION  7A 
FIG.IIO  fi6.ui 


STEEL 

Steel   J-  ■'    jL-4-J.Lft 
Washers^      tyW**     % 

~*-      ::":'^ 

CffSi  lR0N\ 


V- Block  with  Rollers 
(Far  cleaning  Fuse-seat  Thread) 
FIG.  107 
OPERATION  5 


OSTIROM 


Solid  Punch  for  Caulking  Shells 


(••■3—- *l 

f<-2/£5->|  ^iamenei. 

~1l 


driv/ngn-1 


K  -  7f -+*--- "3- 

Black        Red 

FIG.I08 
OPERATION  6 


Black        Cray 


Finish  a       k 

Oie  fpr  Caulking  Shells 
FIG.II3 
OPERATION  7 B 


OPERATION  7-B.  PRESSING  ON  BASE  COVER  WITH 
NIGHT  TRACER 
Transformation — Figs.  112-A  and  112-15.  Machine  Used — 
Watson-Stillman  hydraulic  press,  Fig.  101.  Number  of  Oper- 
ators— Two.  Description  of  Operation — The  base  detonating 
fuse  is  put  in  as  in  operation  7-A,  then  piece  is  taken  by  this 
gang;  the  helper  puts  on  lead  disk  and  night-tracer  base  cover 
and  presses  in  the  calking  ring;  press  operator  then  takes  it 
and  presses  down  the  ring,  as  shown.  Pressure  Required — 
About  2000  lb.  Special  Fixtures — Point-holding  block;  cover- 
ring  nressvtnej  block.  Fig.  113.     Production — 300  oer  8-hr     lav 


FIG.II4 
OPERATION  7C 

OPERATION    7-C.      SCREWING  TN  NIGHT   TRACER 
Transformation — Fig.     114.       Number     of     Operators — One. 
Description  of  Operation — Operator  clamps  a  night  tracer  asr 
a  vise  and,   holding  the  case  in   his  hands,    screws  it  ok  thf 
tracer.     Apparatus  and  Equipment  Used — Common  vise. 


[41] 


SECTION  B-B 


FIG.  116 

OPERAflON  1 


MACHINE  STEEL  (Finish  f±0.0l", 'Case  Haraen) 
FIG.  1 17 


FIQ.  118 


0.375 "Tap  Std 


n 


X 


Four  0.375*1.2  Sfd.  Steel  Setscrews 
Four  0.375" Jam  Nuts 

MACHINE  STEEL     ±0.0l" 
Lower  Punch  Holde*- 


0.5 


4?" 


<--£275"-- 


0.375  Tap  Sfd 
'  1.0" Deep 


For  0.375  FHisterhead  Std  Screws 

MACHINE  STEEL 
Finish f ±0.01" 

Upper  Punch  Holder 

fig.  119 

OPERATION  5 


C5"> 


A=3.35r  B=35b  O0.5I  for  Z95  8:3  Projectiles 
Ar425    B-4.4"  C-0.66"  for  58" Projectiles 
COLD-DRAWN  STEEL       Finish  f  ±0.01* 
Band  Form 


,0} 

\For  0.375 '  FHisterhead j 
Std  Screws  ; 


0.5> 


^ 
^ 


1 


lib 


0.125 


1^ 
8* 


MACHINE  STEEL     Finish fiO.Ol" Harden 
Lower  Punch 


MACHINE  5TEEL        Finish  f±0.01  Harden 
Upper  Punch 


[42] 


FIG.  120 


<5S 


■>\0.!45^- 


Detail  of  Threads 


"to 


H 1.5"- H  0.65" '\*Q&r- L9S"—  -*J 

-4 


0.IE5  >\  H- 


4.6"-- 


vfv 


■  _pwc 


\ 


_ ' HIGHSPEED  STEEL(Harden) 
Finishf±0.005",Finish  Cutting  Edges  Jg    J  I 


F1G.IEI 


X 


/0° 


1                   1       f 

1   o    1 

I 

A 

k- 

->l 

£>/i7/?7.-> 

5" 

<       : 

\7_   _i_FIG.I23 


1         '                Y 

i 

1 

' 

-H  05"  i<- 

U L5". J\ 

FI6.I25 


->l  0.5"  K 


V* 


FIG.I28 


-4' 


"1 


OPERATION  1 


TT 


FIG.  129 


T~ 


X_  LI 


H?/£55* 


OPERATION  1.   CUT  FROM  TUBING  (COPPER) 

Transformation — Fig.  115.  Machine  Used — 15,000-lb.  ad- 
justable-stroke crank  press.  Number  of  Operators  per 
Machine — One.  Special  Fixtures — Shearing  attachment,  Fig. 
116.  Gages — Maximum  and  minimum  width,  Fig.  117.  Pro- 
duction— 3000  in  8-hr.  day. 

OPERATION   2.      ANNEAL 

Number  of  Operators — Three.  Description  of  Operation — 
Bands  are  placed  1000  at  a  time  in  a  large  pan;  four  of  these 
pans  are  put  into  furnace  and  heated  for  %  hr.  to  about  1200 
deg.  F. ;  they  are  then  placed  on  trucks  and  run  out  into  the 
air  to  cool.  Apparatus  and  Equipment  Used — Annealing  pans, 
truck*  furnace.     Production — 40,000  per  8-hr.  day. 

OPERATION  3.     PICKLE 

Number  of  Operators — Two.  Description  of  Operation — 
Bands  are  put  in  baskets  and  pickled  in  1  part  vitriol  and  6 
parts  water  until  scale  is  removed  and  pieces  are  brightened. 
Production — 8000  per  8  hr. 

OPERATION  4.     WASH 

Number  of  Operators — Two.  Description  of  Operation — 
Washed  well  in  cold  water  to  remove  pickle  solution.  Appa- 
ratus and  Equipment  Used — Basket  and  tank.  Production — 
8000  per  day.  Note — Pickling  and  washing  tanks  are  side  by 
side,  and  a  basket  of  pickled  bands  is  simply  hoisted  out  of 
one  tank  into  the  other  and,  after  washing,  suspended  a  short 
time  to  drain. 

.OPERATION  5.     PLANISHING 

Transformation — Fig.  118.  Machine  Used — 15,000  lb.  adjust- 
able-stroke crank  press,  Fig.  102.  Number  of  Operators  per 
Machine — One.  Special  Fixtures — Fig.  119.  Gages — Maximum 
and  minimum,  Fig.  117.     Production — 3000  per  8  hr. 


OPERATION   1.      DRILLING,    COUNTERBORING,    TAPPING 

Transformation  —  Fig.  120.  Machine  Used  —  Brown  & 
Sharpe  automatic.  Number  of  Machines  per  Operator — Three. 
Cutting  Tools — %-in.  twist  drill  (drills  in  J|  in.  for  counter- 
bore);  if-in.  twist  drill;  combination  reamer  and  counterbore, 
Fig.  121;  tap,  Fig.  122;  circle  chamfering  tool,  3  in.  in  diameter; 
circle  cutoff  tool,  3  in.  in  diameter  by  0.10  in.  thick.  Cut  Data 
— 1200  r.p.m.  for  all  but  tapping;  530  r.p.m.  for  tapping. 
Coolant — Zurn  cutting  oil.  Gages — Depth  of  drilled  hole,  Fig. 
123;  maximum  and  minimum  reamed  diameter  plugs,  Fig.  124; 
depth  of  counterbore  feeler,  Fig.  125;  maximum  and  minimum 
diameter  counterbore,  Fig.  126;  diameter  of  thread,  Fig.  127; 
depth  of  thread,  Fig.  128;  maximum  and  minimum  length,  Fig. 
129.  Production — 800  per  8-hr.  day.  Note — Made  from  hard- 
rolled  brass  rod,  %-in.  diameter  ±0.005;  tools  are  used  in 
order  given. 

Turning  of  the  bands  is  done  on  either  a  special  ma- 
chine or  a  lathe,  as  shown  in  Figs.  61  and  62.  On  the 
lathe  two  tools  are  used  in  the  same  slide.  One  roughs 
off  and  edges  the  band,  and  the  other  finishes  it,  being 
guided  by  means  of  a  profile  block  and  follower  at  the 
back.     A  final  dressing  is  given  with  a  mill  file. 

On  the  special  machine,  the  band  is  roughed  off  with 
one  tool  and  then  finished  with  a  form  tool.  A  tool  rest 
is  then  dropped  in  place  and  the  band  smoothed  up  with 
an  end  scraper.  Following  this  the  threads  and  counter- 
bore are  carefully  sized,  as  shown  in  Fig.  63.  This  oper- 
ation, however,  is  not  always  necessary  and  is  only  done 
when  needed. 


[43] 


tllfp 

tim>Uti)tft|!jMi  i1»i)n.(.t,.)'ifilti- 
-  -  -LH JttiHi^HW-tJ-U-tkRRfirUHJ  tMJ 


<L. 


0375 


FIG.  130 


■-e.805" H 


■#---.  - 

FIG.  133 


Adjusting 
/I  Screws 


X    U 


FIG.I3I 
OPERATION  2 


#- 

'<?  Threads  per  Inch,  Left  Hand,  US.  Standard 
FIG.  132 


OPERATION   2.      FACING   END   AND   THREADING 
Transformation — Fig.    130.       Machine    Used — Turret     lathe, 
Fig.    131.      Number    of   Operators    per    Machine — One.      Work- 
Holding   Devices — Collet   chuck.      Cutting   Tools — Facing   tool; 
die  to  cut  0.625    (  +  0.000,  — 0.004)   diameter,    18. left-hand  U.   S. 
Standard  thread.     Cut  Data — Speed,   850  r.p.m.     Coolant — Lard 
oil.      Gages — Maximum    and    minimum    thread    gage,    Fig.    132; 
length  gage,  Fig.  133.     Production — 1200  per  8-hr.  day. 
OPERATION  1.     PUNCHING  INNER  DISK 
Transformation — Fig.     134.      Machine    Used — Small    punch 
press.     Number  of  Operators  per  Machine — One.     Punches  and 
Punch    Holders — Fig.    135.      Dies    and    Die    Holders — Fig.    136. 
Lubricant — Mineral    oil.      Production — -About    75,000    per    8    hr. 
Note — Press  flywheel  runs  70  r.p.m. 

OPERATION  2.  PUNCHING  OUTER  DISK 
Transformation — Fig.  137.  Machine  Used — Small  punch 
press.  Number  of  Operators  per  Machine — One.  Punches  and 
Punch  Holders — Fig.  138.  Dies  and  Die  Holders — Fig.  139. 
Lubricant — Mineral  oil.  Production — About  75,000  per  8  hr. 
Note — Press  flywheel  runs  70  r.p.m. 


OPERATION  3.  TURNING  IGNITION  TUBES 
Transformation — Fig.  140.  Machine  Used — Brown  &  Sharpe 
automatic.  Number  of  Machines  per  Operator— Three.  Cut- 
ting Tools — Drill;  countersink;  formed  tool;  cutoff  tool.  Cut 
Data — Spindle  runs  2400  r.p.m.  Coolant — Zurn  Cutting  oil. 
Gages — Combination,  Fig.  141.  Production — 3500  per  8  hr 
Note — Made  from   ^-in.  diameter  brass  rod. 

OPERATION  4.  MILLING  IGNITION  TUBES 
Transformation — Fig.  142.  Machine  Used — Hand  miller. 
Number  of  Operators  per  Machine — One.  Work-Holding  De- 
vices— Miller  vise  and  formed  jaws,  Fig.  143.  Cutting  Tools — 
Milling  cutter,  1%  jn.  in  diameter,  20  teeth.  Cut  Data — Cutter 
runs  600  r.p.m.     Production — 4000  per  clay. 


OPERATION   5. 


ASSEMBLING   IGNITION   TUBE   TO 
OUTER  DISK 


Transformation — Fig.  144.  Number  of  Operators — One. 
Apparatus  and  Equipment  Used — Bench  riveter.  Fig.  145. 
Production — 1600  per  8  hr. 


OS    TOOL  STEEL 
i     FinishftO.005 
■  -*■       Harden 
5+op 


t, ,» J  MACHINE  STEEL    Finish f±  12002" 

0.25"*  0.375"St"d.  Filisferhead  Steel  Screws 
Stripper 
FIG.I36   OPERATION  I, 


aS5"tZ"Stk  Steel  Setscrews 
QcSVtfSfd.Steel  Setscrews     CAST  IRON  ±0.01 

Die  Holder 


[44] 


The  next  in  order  is  a  thorough  inspection  of  the  en- 
tire case  by  a  group  of  regular  inspectors  who  also  divide 
the  shells  according  to  weight,  after  which  the  inside  back 
of  the  threads  is  sandblasted,  as  shown  in  Fig.  83.  The 
shells  are  laid  in  a  row  on  a  wooden  grating,  open  ends 
out,  and  the  operator  thrusts  the  sandblast  nozzle  into 
each  in  turn.  This  thoroughly  cleans  out  the  part  of  the 
cavity  that  has  not  been  machined. 

The  hydraulic  testing  is.  done  in  the  apparatus  shown 
in  Fig.  84  and  in  detail  in  Fig.  90.  The  test  is  an  ex- 
ternal one,  a  plug  being  screwed  into  the  base  to  make  it 
water-tight ;  then  the  shell  is  hoisted  into  the  testing  cyl- 
inder by  means  of  a  chain  block  hooked  to  a  screw-eye  in 
the  base  plug.  The  testing  cylinder  slides  on  ways,  so 
as  to  be  moved  from  loading  to  testing  positions  under 
the  press  ram.  The  moving  of  this  testing  cylinder  is 
accomplished  by  the  operation  of  a  small  hydraulic  cylin- 
der at  the  back  of  the  press,  the  connecting-rod  of  which 
is  coupled  to  the  cylinder,  as  can  be  seen  in  Fig.  84.  Af- 
ter the  cylinder,  full  of  water  and  with  the  shell  inside,  is 
in  place  under  the  press  ram,  the  ram  is  lowered  and 


pressure  applied  until  it  is  equal  to  350  tons,  or  about 
20,000  lb.  per  sq.in.  on  the  surface  of  the  shell.  This 
test  shows  whether  there  are  any  flaws,  weak  spots  or 
blow-holes  leading  into  the  interior. 

The  first  operation  directly  connected  with  the  loading 
of  the  explosive  charge  is  painting  of  the  interior  with 
acid-proof  paint,  the  various  loading  operations  being  in 
the  following  order : 

1.  Painting  interior  by  nana 
1-A.  Painting   interior  with  a  spray 

2.  Weighing 

3-A.  Pilling   with   trinitrotoluol 
3-B.  Compressing  the  trinitrotoluol 

4.  Reaming  for  fuse  case 

5.  Cleaning  threads  and  counterbord 

6.  Painting  outside 

7-A.  Putting  in  fuse   (without  night  tracer) 
7-B.  Pressing  on  base  cover  (with  night  tracer) 
7-C.  Screwing   in  night  tracer 

Painting  of  the  interior  may  be  done  in  either  one 
of  two  ways :  By  hand,  using  the  outfit  shown  in  Fig.  92, 
or  with  a  spray,  using  the  apparatus  shown  in  Fig.  85. 
The  hand  method  is  slower,  but  may  be  used  where  a  spray 
is  not  available  or  when  it  is  out  of  order.  The  operator 
fills  the  cavity  to  the  threads  with  paint  and  pours  it  out, 


r^ 


r 


•4% 

\<-aiS" 


~f3&YwSnu3 


TI 


-=z^^l 


r+aooo. 

0.002" 


A 


Outer  Disk  Punch 
FIG.  138 


-Pfffoilf)! 

uj uij u 


~rm~ 


TAT 


aifeltpi 


Mi 


m 

'Ml  » 


©  \<a825"*\ 

0.25"TapStd.     k  0.69"A  ■ 


0 


a 


FIG.  140 


h- 


0.0I8"~*\V 


■2.5" 


r 4 

H  \~-0.022Max    , 


3.375"- 


-~|  0.51' 


\<-Ream\ 

—  v**i 


•5 


r- 

TOOL'STEEL 


~-3"~ 


— «1 


tQ, 


0.081  Drill 

(•T   0.8"---: 


0.25"Drill 


Finish  f  ±0002, Harden        , 

■  .-am" 

*t\*-Ream 


§ 


wssx.       esq 


X 

A. 


MACHINE  STEEL  Finish f  ±0.01" 
0.25""l.25"Std  Headless  Sieel  Setscrews 
0.25*05"Sfd.  Headless  Steel  Seiscrews 

X-Q95f±Q002"->\<-a952"±a002"^\ 

"&9 * 


ai5±aor^  f^/ream       *uc^     .  <-, r,  - 

r  r- -'  Hi — '        /'  "     ' '  "^-|     *  ~*W.308%Mi, 


'•fa\> — ~l 

*,02 

'^■05" 
«- 


S3 
l_ 

T" 

*\  f<:-aoi* 

■»\a3l2'U-Max. 
MACHINE  STEEL    Finish f  ±0.01"  Case  Harden 

FIG.  141 


FIG.  143 


0.5l"Diam.- 
FIG.I44 


[45] 


OPERATION  1.  LOADING  ILLUMINATING  POWDER 
Transformation — Pig.  146.  Number  of  Operators — Three. 
Description  of  Operation — Tracers  are  filled  and  mixture  com- 
pressed in  a  bombproof  with  the  same  type  of  Riehle  press 
used  for  trinitrotoluol  loading;  tubes  are  first  filled  with 
illuminant  powder  and  placed  10  at  a  time  in  the  fixture 
shown  in  Fig.  147  and  given  40,000  lb.  total  pressure,  equal 
to  4000  each;  this  is  repeated  three  times.  Apparatus  and 
Equipment  Used — Riehle  hydraulic  press;  holding  fixture  and 


OPERATION  5.  TRIMMING  END 
Transformation — Pig.  153.  Machine  Used — Small  turret 
lathe.  Number  of  Operators  per  Machine — One.  Work-Hold- 
ing Devices — Collet  chuck.  Cutting  Tools — Fig.  154.  Cut 
Data — Spindle  runs  350  r.p.m.  Production — 2000  per  day.  Note 
— Tracer  is  chucked  and  end  of  tube  faced  off  until  about  0.002 
in.  from  outer  disk;  inside  of  mouth  and  disk  is  then  coated 
heavily  with  nonacid  paint,  except  opening  in  ignition  tube: 
complete  night  tracer  is  shown  in  Fig.  155, 


*$£/^s^$%j$ft$isf  1        :•       M§:±h:-miMM;$$m0MZ$£&  H§.§    M  0.3^-05^ 


FIG.  153 


FIG.  151 


[*-—Q5"±0.0Ol"~--A 

T00LSTEEL(Harden) 
Finish/ 1 0.005" 


f 


FIG.  146  &  147  OPERATION  I 
_*    FIG.  148  &  149  OPERATION  2 
WIS6  FIG.  150  OPERATION  3 
T   FIG.I5I&I5E  OPERATION  4 

FIG.I53,I54&I55  OPERATION  5 


Agr  Igniting  Mixture-^ 


■«- 03' >*<■- 0.5"- 


FIG.  154 


167- -gr. Illuminating  Ponder--'  24-gr.  Black  Fbnc 

FIG.I55 


l?-gr  Delay 
Mixture 


pressing  punches   for   10   tubes;   small-handled   powder   meas- 
ures or  dippers.     Production — 1000  per  8-hr.  day. 

OPERATION  2.  COUNTERBORING 
Transformation — Fig.  148.  Machine  Used — Small  turret 
lathe.  Number  of  Operators  per  Machine — One.  Work-Hold- 
ing Devices — Collet  chuck.  Cutting  Tools — Counterbore,  Fig. 
149.  Cut  Data — Spindle  runs  350  r.p.m.  Production — 2000  per 
8-hr.  day. 

OPERATION  3.  LOADING  IGNITION  MIXTURE 
Transformation — Fig.  150.  Number  of  Operators — Three. 
Description  of  Operation — 4  gr.  igniting  mixture  is  poured 
into  drilled  and  counterbored  hole  and  shaken  down;  24  gr. 
black  powder  is  then  poured  on  top  of  this  and  a  brass  inner 
disk  placed  on  top  of  the  powder;  each  tube  is  given  4000  lb. 
pressure,  using  the  same  fixture  as  for  illuminant;  in  loading, 
two  holders  are  used  with  one  set  of  punches  in  the  press,  and 
they  are  employed  alternately,  as  the  illuminating  and  igniting 
powder  are  loaded  in  turn.  Apparatus  and  Equipment  Used — 
Same  as  for  operation  1.     Production — 1000  per  8-hr.  day. 

OPERATION  4.  LOADING  RETARDING  MIXTURE 
Transformation — Fig.  151.  Description  of  Operation — On 
top  of  the  inner  disk  is  poured  12  gr.  delay  mixture;  the  outer 
disk  is  put  on,  the  holes  in  the  two  disks  being  placed  on 
opposite  sides;  two  tubes  are  compressed  at  once  at  14,000  lb. 
total  pressure,  or  7000  each,  using  the  holders  and  punches 
shown  in  Fig.  152.  Apparatus  and  Equipment  Used — Riehle 
hydraulic  press  in  bombproof.     Production — 1800  Der  8-hr.  dav 


then  passes  the  shell  to  another,  who  wipes  the  threads 
Avith  waste.  The  spray  method  is  far  quicker  and  does 
not  smear  the  threads  so  much,  as  the  operator  turns  on 
the  spray  after  the  nozzle  is  inside  the  shell  and  turns  it 
off  before  removal. 

The  weighing  of  the  case  is  for  the  guidance  of  the 
fillers,  the  weight  being  chalked  on  each  shell,  as  shown 
in  Fig.  93.  The  fillers  work  in  gangs  of  three,  one  fill- 
ing, one  carrying  and  refilling,  and  one  operating  the 
press.  These  operators  shift  positions  or  help  on  the 
different  operations,  as  occasion  demands  in  order  to 
balance  the  work. 

The  high  explosive,  or  trinitrotoluol,  is  a  yellowish- 
white  powder  not  dangerous  in  the  ordinary  •  sense,  until 
compressed;  but  when  compressed  and  fired  by  means  of 
a  detonator,  it  is  one  of  the  most  powerful  explosives 
known. 


[46] 


Compressing  the  trinitrotoluol  is  done  with  a  hydraulic 
press  placed  in  a  concrete  bombproof  room,  the  oper- 
ator watching  the  actual  work  by  means  of  a  mirror,  as 
shown  in  Fig.  87.  A  shell  in  the  holding  fixture  with  the 
punch  or  rammer  ready  to  descend  is  shown  in  Fig.  88. 
The  rammer  presses  the  explosive  solidly  into  the  shell 
and  leaves  a  cavity  for  the  insertion  of  the  detonator. 
This  cavity  afterward  has  to  be  reamed  out  to  size,  which 
is  done  as  shown  in  Fig.  97.  The  reamer  is  held  in  a 
chuck  and  passes  over  two  jaws  of  a  steadyrest,  which  not 
only  steadies  the  reamer,  but  acts  as  a  stop  for  the  depth 
of  the  cut.  Fig.  105  shows  a  stop  collar  on  the  reamer, 
but  in  the  actual  shop  practice  this  is  no  longer  used. 
The  operator  places  a  shell  on  the  guiding  block  and 
presses  it  forward  onto  the  revolving  reamer  until  the 
end  of  the  shell  contacts  with  the  steadyrest  jaws. 

After  being  reamed  out,  the  threads  and  counterbore 
have  to  be  cleaned.  This  is  done  by  placing  the  shell  on 
the  fixture  shown  in  Fig.  98  and  using  the  hook  tool  there 
shown  to  clean  the  threads  as  the  operator  rotates  the 
shell  by  hand.  The  counterbore  is  scraped  out  with  a 
scraper  made  from  an  old  file.  Following  these  operations 
the  shell  is  painted  from  point  to  band,  while  held  as 
shown  in  Fig.  99,  the  operator  applying  the  paint  with 
wide  brushes. 

The  detonator  fuse  is  next  screwed  in,  with  the  shell 
held  in  a  bench  vise,  Fig.  100.  A  detonator  is  shown  at 
A.  If  the  threads  are  a  little  tight,  a  tap  B  is  run  in. 
If  the  hole  is  not  quite  deep  enough  or  has  not  clearance 
enough,  it  is  made  larger  by  pounding  and  rotating  the 
reamer  C  in  the  hole.  With  everything  clear,  the  fuse  is 
screwed  home  with  the  spanner  D  and  locked  to  the 
notches  in  the  shell  with  a  punch  and  hammer.  In  case 
no  night  tracer  is  to  be  used  on  the  shell,  lead  plugs  are 
pounded  into  the  spanner  holes,  and  a  sheet-metal  cover 
E  is  put  over  the  end  with  the  edges  in  the  cover  groove. 
A  calking  lead  ring  F  is  then  pounded  into  the  groove 
as  indicated  in  Fig.  109. 

Where  a  night  tracer  is  used,  the  fuse  is  put  in  in  the 
same  way,  the  lead  slugs  are  pounded  in,  the  special  cover 
put  on  and  a  lead  ring  put  in  place.  This  ring,  however, 
is  not  pounded  in  as  previously  described,  but  is  pressed 
in  as  shown  in  Fig.  101,  the  process  being  graphically 
shown  in  Figs.  112-A  and  112-B.  Screwing  in  of  the 
night  tracer  consists  in  placing  the  tracer  in  a  vise  and 
screwing  the  shell  onto  it  by  hand. 

Making  the  Band 
Operations  on  making  the  copper  band  are  as  follows: 

1.  Cut  from  tubing 

2.  Anneal 

3.  Pickle 

4.  Wash 

5.  Planish 


The  list  of  operations  is  almost  self-explanatory;  the 
details,  however,  are  given  under  the  proper  headings. 
The  last  operation,  planishing,  is  really  a  sizing  for  width, 
as  the  band  is  pressed  between  two  flat  dies,  as  shown  in 
Fig.  102. 

Making  Night  Tracer 

1.  Drilling,   counterboring,   tapping 

2.  Facing  end  and  threading 

Night  tracers  are  made  from  brass  rod  in  automatic 
screw  machines ;  the  order  of  procedure  is  as  given  above 
and  is  the  usual  standard  screw-machine  practice  in 
every  way. 

Facing  and  threading  of  the  closed  end  is  done  in  a 
hand  screw  machine. 

Making  Night-Tracer  Disks 

1.  Punching  inner  disk 

2.  Punching  outer  disk 

3.  Turning  ignition  tubes 

4.  Milling  ignition  tubes 

5.  Assembling  ignition  tube  to  outer  disk 

The  making  of  the  disks  is  a  punch-press  job,  as  shown 
by  the  punches  and  dies,  Figs.  135,  136,  138  and  139. 
The  ignition  tubes  are  made  on  automatic  screw  machines 
from  brass  rod  and  are  milled  off  at  a  sharp  angle  on  the 
outer  end  in  a  hand  miller.  The  assembling  of  the  ig- 
nition tube  to  the  outer  disk  is  done  by  hand,  and  then 
the  tube  is  riveted  fast  in  the  disk  in  the  bench  riveter, 
Fig.  145. 

Loading  Night  Tracer 

1.  Loading  illuminating  powder 

2.  Counterboring 

3.  Loading  ignition  mixture 

4.  Loading  retarding  mixture 

5.  Trimming  end 

The  loading  of  the  night  tracer  with  the  illuminating 
powder  is  done  in  a  hydraulic  press,  using  the  holders  and 
punches  shown  in  Fig.  147.  Several  fillings  and  press- 
ings are  needed  to  complete  the  work.  After  the  illumi- 
nating powder  has  been  pressed  in,  it  is  machined  out  at 
the  open  end  of  the  tracer  in  a  small  turret  lathe,  using 
the  combination  drill  and  counterbore,  Fig.  149.  The 
object  of  drilling  into  the  illuminating  powder  is  to  give 
the  ignition  mixture  a  better  chance  of  surely  doing  its 
work.  The  ignition  mixture  is  next  put  in  and  the  inner 
disk  pressed  in.  On  top  of  this  a  slow-burning  powder  is 
placed,  and  then  the  outer  disk  is  pressed  in.  Finally,  the 
end  of  the  tracer  is  faced  off  with  the  tool  shown  in  Fig. 
154.  The  tracer  is  now  ready  to  be  screwed  into  the  base 
of  the  shell.  It  may  be  noted  that  the  thread  on  the  base 
of  the  tracer  is  left-hand,  so  that  there  is  no  tendency  to 
unscrew  as  the  shell  is  fired  from  the  £un. 


[47] 


Three-Inch  United 


Navj^Projectiles 

By  Lieut.  A.  G.Dibrell  * 


SYNOPSIS — Shells  of  the  size  described  here  are  required  in  large  numbers  for  use  in  guns 
placed  on  destroyers  or  on  boats  of  the  type  known  as  submarine  chasers.  These  shells  differ 
considerably  from  the  3-in.  ones  used  in  field  guns  or  coast  artillery,  which  have  been  previ- 
ously described.     The  various  machine  operations  are  given  with  considerable  detail. 


TT 


The  manufacture  of  munitions  in  navy  yards,  an  ex- 
perimental enterprise,  inaugurated  last  year,  has  proved 
signally  successful  at  Puget  Sound.  As  a  general  propo- 
sition in  peace  times,  the  Government  unquestionably  is 
wise  in  giving  such  contracts  to  private  individuals,  there- 
by releasing  its  own  plants  for  the  more  important 
repair  work  on  ships.  But  the  Government  should 
nevertheless  be  able  to  perform  any  class  -of  work  necessary 
for  the  proper  supply  of  the  fleet  in  all  its  essentials  and 
have  definite  information  at 
hand  for  the  use  of  individ- 
uals, should  an  emergency 
arise.  In  the  machining  of 
projectiles  there  is  a  great 
amount  of  preparatory  work 
necessary — special-tool  man- 
ufacture, gage  manufacture 
and  the  equipping  of  ma- 
chines— before  the  projec- 
tiles can  be  properly  and 
economically  machined.  Ev- 
idence of  this  has  been  ob- 
tained in  every  munition 
plant  visited.  Hundreds  of 
rejected  shells  were  seen, 
most  of  which  were  made 
during  the  early  stages  of 
the  shops'  contracts.  This 
was  owing  to  the  fact  that  the  manufacturers  had  only 
drawings  and  specifications  to  guide  them  in  the  selection 
of  necessary  machines  and  equipment.  The  Government 
should  furnish  the  American  manufacturers   with  con- 


FIG.  1. 


•United  States  Navy,  Submarine  Division. 


crete  actual  working  examples  of  all  the  minute  details 
necessary  for  the  proper  and  efficient  manufacture  of 
munitions. 

Owing  to  the  great  number  of  3-in.  shells  that  will 
probably  be  required  to  supply  the  submarine  chasers  and 
patrol  boats  now  building,  a  description  of  the  method 
adopted  at  Puget  Sound  is  here  given.  The  machines 
used  are  common  to  all  shops,  and  it  is  hoped  that  this 
description  will  enable  private  individuals  to  equip  their 

plants  and  be  ready  to  start 
the  work  of  machining  as 
soon  as  forgings  are  re- 
ceived. Fig.  1  gives  the  di- 
mensions of  the  3-in.  forg- 
ings furnished  the  navy  yard 
by  the  American  Car  and 
Foundry  Company.  A  radial 
drill  is  equipped  for  the  first 
operation  for  the  3-in.  shells. 
The  chuck  shown  in  Fig.  2 
is  a  universal  three-jaw 
lathe  chuck.  In  the  base  of 
the  chuck  is  a  center  point. 
The  female  center  shown  in 
the  nib  on  the  point  of  the 
rough  forgings  fits  over  this 
male  point.  The  jaws  of  the 
chuck  are  then  set  up  to 
hold  the  forging,  while  the  small  hole  in  the  base  is  drilled 
out  to  Jf  in.  in  diameter.  The  center  in  the  nib  is  con- 
centric with  the  cavity  of  the  forging,  and  the  method  of 
chucking  and  drilling  the  fuse  hole  in  the  base  of  the 
shell  brings  this  hole  also  concentric  with  the  cavity.    The 


DETAILS  OP  UNITED  STATES  NAVY  THREE-INCH 
COMMON  PROJECTILE 


[48] 


jaws  of  the  chuck  grip  the  shell  about  2|  in.  from  the 
base.  The  surface  of  the  forgings  is  somewhat  distorted 
by  the  dies  in  closing  in  the  base,  and  the  chuck  must 
grip  below  this  part  of  the  forging.  The  swinging  arm 
carrying  a  hardened  bushing  is  closed  to  engage  a  perma- 
nent stop  and  fastened  in  place  by  a  wing  nut,  as  shown. 


fig.  5. 

A  J|"m-  twist  drill  running  at  280  r.p.m.  and  with  a 
feed  of  0.008  in.  is  used  to  enlarge  the  hole.  This  permits 
the  gage  rods,  shown  at  A  and  C,  Fig.  3,  in  operation 
•2  to  enter,  and  also  removes  rough  stock  for  chasing  the 
threads  for  the  fuse.  The  lubricant  is  soap-water  com- 
pound, which  has  proved  very  satisfactory  for  this  work. 


FIG.    3.      ARRANGEMENT   FOR   OPERATION   2 

Two  machines  are  equipped  for  performing  the  second 
operation,  as  this  operation  requires  the  greatest  amount 
of  time  to  complete.  A  16  x  20  x  1^-in.  Warner  & 
Swasey  belt-driven  turret  lathe  and  an  18  x  24  x  3-in. 
Jones  &  Lamson  belt-driven  turret  lathe  are  used.     Fig. 


FIG.  4.  TURNING  BASE  AND  BAND  SCORE 


3  shows  the  Warner  &  Swasey  lathe  fitted  for  performing 
the  operations.  The  forging  is  held  in  a  collet  chuck  of 
six  segments,  separated  by  small  springs,  and  each 
segment  is  knurled  to  give  a  better  grip.  The  forging 
is  first  tested  for  eccentricity  by  means  of  the  indicator  A. 
The  finger  travels  back  and  forth  on  the  walls  of  the 

cavity  and  moves  the 
pointer  along  the  grad- 
uations shown.  If  the 
movement  of  the  point- 
er exceeds  the  limits 
of  the  graduations,  the 
forging  will  not  clean 
up  and  is  marked  and 
set  aside.  The  base  of 
the  shell  is  next  faced 
off  by  the  tool  B  on 
the  turret  head  at- 
tached to  the  crossfeed 
to  suit  the  gage  C  on 
the  lathe  turret.  This 
establishes  the  dimen- 
sion 7.42  in.  from  the 
nose  of  the  cavity  to 
the  face  of  the  base. 
turning  base  and  band  score  About  3  in.  of  the  base 

is  next  turned  to  a 
diameter  of  2.995  in.  by  the  tool  D,  finished  by  the  tool 
E  to  2.980  in.  and  the  band  score  cut  to  a  diameter  of 
2.850  in.  and  0.630  in.  wide  by  the  tool  F.  The  tool 
G  rounds  the  base  to  the  fillet  shown  on  the  drawing. 
The  stop  H  is  set  for  the  tools  D,  F  and  G. 

This  machine  is  shown  in  Fig.  4 ;  the  view  of  the  shell 
A  on  the  lathe  turret  and  B,  Fig.  11,  show  the  machining 
done.  The  turret  head  at- 
tached to  the  cross-slide 
is  an  ordinary  square  tur- 
ret head  holding  tools  at 
the  corners.  The  lubri- 
cant used  in  this  opera- 
tion is  a  compound  of 
soap  and  water.  The  cut- 
ting tools  are  all  of  tung- 
sten tool  steel.  The  Jones 
&  Lamson  turret  lathe, 
Fig.  5,  works  continu- 
ously on  operation  2,  the 
tool  layout  being  shown 
in  Fig.  6.  All  selective 
gear  is  removed  from  the 
spindle  drive,  and  a  single 
back-gear  shaft  is  in- 
stalled. The  forging  is 
gripped  in  a  draw-in  collet 
chuck,  operated  by  hand 
lever,  the  female  center 
hole  in  the  nib  of  the  forg- 
ing fitting  over  a  male  center  point  at  the  rear  of  the  chuck. 
The  depth  of  the  chuck  allows  about  3£  in.  of  the  forging 
at  the  base  clear  for  machining.  The  diameter  at  the 
base  is  rough  turned  by  the  tool  A  at  45  ft.  per  min. 
speed,  0.01-in.  feed  and  &-in.  cut.  (Where  fins  have 
been  left  by  the  closing-in  die  at  the  base,  the  depth  of 
cut  is  more  than  ^  in.)  '  The  turret  is  indexed  one 
position,  a  straight  gage  rod  is  inserted  in  the  base  hole, 


FIG.   2.     DRILLING  CENTERS 


[49] 


and  the  forging  is  faced  off  at  the  base  by  the  tool  B 
the  correct  length,  which  in  this  case  is  7.042  in.  from  the 
extreme  point  of  the  cavity  in  the  shell. 


center  supported  through  the  turret  hole,  suitably  ar- 
ranged for  quick  disengagement  when  the  work  is  on- 
chucked.  The  roughing  cut  is  taken  over  the  body 
forward  of  the  band  score  to  the  bourrelet,  as  shown  in 
Fig.  8  and  at  C,  Fig.  11.  Two  tools  are  used  in  the 
special  carriage  mentioned  above  to  shorten  the  distance 
of  tool  travel.    A  speed  of  55  ft.  per  min.,  ^-in.  feed  and 


jj        A,  Roughing  Cut 

B.  face  off  end  to  suit  Gage 
C  first  Cut  of  Band  Score 
D,  Second 'Operation of BandScore, 
Diam.  2S50>/ Width  0.650" 
E  Rounding  Corner 
r,  finishing  Cut 
b,  Gage  for  Determining  End  Cut 


FIG.  6.   TOOL  LAYOUT  FOR  OPERATION  2 

The  work  runs  at  the  same  speed  and  feed  with  f^-in. 
cut.  The  turret  is  again  indexed,  and  the  band  score  is 
roughed  out  with  the  narrow  tool  C  and  finished  with 


FIG.    13.      TESTING    FOR    ECCENTRICITY 

3%-in.  cut  are  adopted  for  this  operation.  Forgings  are 
run  through  in  lots  of  100  on  the  roughing  cut  and 
then  run  through  for  a  finish  cut.  In  this  manner,  time 
is  saved,  owing  to  the  rapidity  with  which  forgings  can 
be  chucked  and  unchucked  and  to  the  fact  that  the 
roughing  cut  does  not  require  accuracy.    For  the  finishing 


FIGS.  7  AND  9. 
Fig.    7 — Details   for    operation    3. 


kJ  l 

OPERATION    4 

ROUGH  TURN  RADIUS  POINT 

N?  I,  Cutting  off  Tit 

/V.V,  Rough  Turn ■  Radius  /bint 


TURNING  OPERATIONS 

Fig.    9 — Turning   operations   on   the   point 


^\  OPERATION  5 

\/7NISIf  TURNING 
USING  ONC  TOOL 


90 lb  Air  Pressure 


the  f-in.  wide-nose  tool  D.  The  feed  and  cut  are  regu- 
lated by  hand  through  a  cutting-off  lever.  The  turret  is 
again  indexed,  and  the  tool  E  rounds  off  the  corner  of  the 

base  with  the  machine  run- 
ning at  the  same  speed. 
The  finish  cut  is  taken 
between  the  groove  and  the 
base  of  the  forging  on  the 
next  index  of  the  turret, 
the  tool  F  being  used.  The 
speed  of  the  work  is  120  ft. 
per  min.,  ^V*11-  ^ed,  0.007- 
in.  cut.  The  lubricant 
is  soap-water  compound. 
Fig.  7  shows  the  Warner 
&  Swasey  lathe  fitted  for 
operation  3.  The  lathe  has 
a  special  turning  carriage 
fitted  to  the  ways,  being 
pushed  forward  by  a  regu- 
lar turret  saddle,  which 
furnishes  the  power  feed. 
The  forging  is  gripped  by  a  draw-in  chuck  at  the  base  end, 
which  has  been  finished  in  operation  2.  The  female 
center  in  the  nib  of  the  forging  runs  upon  the  male 


cut  the  work  is  rechucked  as  before;  the  tools  A  and  B, 
Fig.  7,  finish  cut  the  body,  and  the  tool  C  on  the  turret 
finishes  the  bourrelet  to  micrometer  sizez.  On  the  finish 
operation,  175-ft.  speed,  ^-in.  feed  and  0.007-in.  cut 
are  used.  Soap  and  water  compound  is  employed  in 
both  operations. 

Operation  4  consists  in  roughing  the  radius  point,  and 
operation  5  in  finishing  the  point.     Both  these  operations 


FIG.   14.     MARKING 
THE    BASE 


m*^^^ 

iftft*?,-** *  HE 

/  - 
K.'i  J  jl 

~y*j  ^i 

FIG.   8.     TURNING  FORWARD  OF  BAND  SCORE 


[50] 


are  performed  in  the  same  machine,  a  2  x  24  x  13-in. 
Jones  &  Lamson  turret  lathe,  from  which  the  back  gear- 
ing has  been  removed  and  a  wide-belt  drive  connected 
directly  to  the  spindle.  The  diameter  of  the  spindle 
being  smaller  than  the  diameter  of  the  projectile,  a 
special  outboard  bearing  A,  Fig.  9,  is  fitted  to  take  the 
overhang  from  the 
forward  journal. 
The  shell  is  gripped 
just  back  of  the  bour- 
relet  in  a  collet  chuck 
B.  The  cross-slide 
from  an  engine-lathe 
carriage  is  bolted  to 
the  swivel  base  D  of 
a  planer  vise,  and 
this  rig  is  bolted  se- 
curely to  the  ways  of 
the  turret  lathe  in 
correct  position  for 
turning  the  radius 
point  on  the  fixed 
center,  as  shown  in 
Fig.  10.  The  cres- 
cent-shaped casting, 
which  is  shown  at  E, 
is  bolted  to  ways  to 
furnish  a  bearing  sur- 
face beneath  the  tool 

slide  F.  It  has  a  brass  wearing  shoe  of  greater  radius 
than  the  cutting  tool,  to  prevent  springing;  a  link  G 
connects  the  base  to  the  turret  saddle  H,  and  the  circu- 
lar movement  for  radius  turning  is  thus  derived  from  the 
straight-line  travel  of  the  saddle.  The  ordinary  feed 
mechanism  of  the  turret  lathe  gives  automatic  power  feed. 
The  tool-holding  block  carries  three  tools,  as  shown.  The 
swivel  is  moved  into  position  so  that  the  cross-slide  en- 
gages a  stop  screw  fastened  on  the  face  of  the  outboard- 
spindle  bearing,  and  the  cutting-off  tool  I  is  then  in  posi- 
tion to  cut  off  the  nib,  the  feed  being  made  by  hand  screw. 


distance  from  the  center  of  the  swivel  D;  both  tools, 
therefore,  cut  in  the  same  plane.  By  using  the  two 
tools  the  entire  surface  of  the  radius  point  is  machined 
when  the  tool  block  moves  one-half  the  distance  from 
the  point  to  the  bourrelet.  Owing  to  the  great  excess 
of  metal  on  this  part  of  the  forgings,  it  has  been  found 


FIG.    10.      TURNING    RADIUS   POINT 


necessary  to  take  two  roughing  cuts.  Furthermore,  the 
radius  point  is  not  forged  concentric  with  the  straight 
body.  The  machine  runs  at  a  speed  of  200  r.p.m.,  and 
the  first  roughing  cut  is  approximately  \  in.  deep  and 
y-^^pin.  feed.  For  the  second  roughing  cut,  the  machine 
runs  at  the  same  speed,  which  gives  about  150  ft.  per 
min.  at  the  largest  diameter,  with  a  cut  -^  m-  deep. 
Lots  of  about  100  are  rough  turned,  and  the  machine  is 
shifted  for  finish-turning  operation  5. 

For  the  finishing  cut  the  forging  is  chucked  as  before ; 
the  feed  is  reversed  so  that  the  finishing  tool  L  will 


FIG.  11.     SHELLS  IN  DIFFERENT  STAGES  OF  MACHINING 


The  turret  saddle  II  is  moved  by  hand  until  the  tool 
J  is  at  the  nose  of  the  forging,  the  depth  of  the  cut 
being  adjusted  by  means  of  the  regular  crossfeed  screw. 
The  tools  K  and  J  are  permanently  set  at  the  same 


travel  from  the  bourrelet  to  the  point  of  the  shell.  For 
finishing,  a  speed  of  240  r.p.m.  is  used,  about  180  ft. 
per  min.  at  the  largest  diameter,  0.01-in.  feed  and  0.015- 
in.  cut.     The  lubricant  for  both  operations  is  soap-water 


[51] 


compound.  A  jet  for  each  tool  is  so  regulated  that  it 
may  be  utilized  on  one  or  all  tools,  as  desired.  The  shell 
at  D,  Fig.  11,  shows  the  condition  after  leaving  this 
machine. 

Operation  6*  consists  of  weighing  and  gaging  to  this 
point  (outside  of  forging  finished)   and  again  after  the 


FIG.    15.      TURNING   SINUSOIDAL   WAVES 


copper  band  has  been  finished.  The  leadingman  and  the 
inspector  perform  this  operation.  Fig.  12  shows  the  scale 
and  various  gages.  Fig.  13  shows  the  gage  for  testing 
the  3-in.  projectiles  for  eccentricity.  The  shell  is  laid 
on  the  rollers;  the  finger  of  the  gage  is  inserted  through 
the  fuse  hole,  as  shown,  and  is  held  against  the  walls  of 
the  cavity  by  the  small  spring  on  the  block  C,  which 
slides  in  a  slot  milled  in  the  casting.  The  pointer 
indicates  on  the  blocks  A  and  B  the  amount  of  eccen- 
tricity, the  graduations  being  in  thousandths  of  an  inch. 
The  shell  is  revolved  on  the  rollers  by  hand.     The  fol- 


Fig.  14  shows  the  device  for  marking  the  base,  opera- 
tion 7.  It  consists  of  the  cast-iron  base  A  supporting 
the  two  uprights  E,  across  the  top  of  which  is  the  yoke  M. 
On  top  of  M  is  an  air  cylinder  L  operated  by  the  lever  K. 
The  marking  die  J  is  supported  by  the  plate  G.  The 
counterweights  D  are  attached  to  the  plate  G,  which  slides 

on  the  two  uprights 
for  lifting  the  plate 
and  die  after  mark- 
ing. The  conical 
chuck  H  holds  the 
shell,  base  up,  for 
marking.  The  weight 
being  up  at  the  posi- 
tion shown  by  the 
dotted  lines,  the  ac- 
tion is  as  follows: 
The  die  is  placed 
over  the  base  of  the 
upturned  shell  and 
secured.  The  air  ex- 
haust valve  in  the 
cylinder  is  opened, 
permitting  the 
weight  B  to  fall  by 
gravity  from  a  height 
of  10  in.  There  is  a 
small  rebound,  but 
this  does  not  affect 
the  marking.  The  air 
pressure  is  turned  on,  lifting  the  weight.  The  die  is 
removed,  the  counterweights  lifting  the  die  and  plate. 
The  shell  is  removed — another  one  put  in  the  chuck. 

Operation  8  is  performed  in  an  old-style  wire-feed  belt- 
driven  Bardons  &  Oliver  1\  x  14  x  16-in.  screw  machine, 
Fig.  15.  In  order  to  obtain  sufficient  diameter  to  grip 
the  base  of  the  projectile,  a  special  draw-in  chuck  was 
made  for  the  spindle.  A  three-throw  cam  of  tempered 
steel  is  secured  to  the  outside  of  the  chuck  body,  to  give 
the  tool  the  movement  necessary  for  cutting  the  sinusoidal 
ribs  in  the  copper-band  score.     Fig.  16  shows  the  tool 


FIG.   12.     INSPECTING,  WEIGHING  AND  TESTING 


lowing  tests  are  made  here :  Gage  bourrelet  for  size ;  gage  set  up  for  this  operation.     A  comb-shaped  tool  is  held 

body  for  size;  test  for  eccentricity;  gage  length;  weigh  in  a  block  on  the  cross-slide,  as  shown  at  A.    "When  the 

in  rough  and  finished;  gage  copper  band'  test  capacity  slide  is  moved  forward,  this  tool  shaves  the  body  of  the 

of  cavity;  gage  fuse-hole  threads.  band  score  to  the  correct  width  and  diameter,  leaving 


[52] 


ribs  sufficiently  wide  to  permit  the  tool  C  to  finish  the 
sinusoidal  waves.  The  tool  A  travels  underneath  the  forg- 
ing until  the  slide  engages  an  adjustable  stop,  at  which 
time  the  undercutting  tool  B  at  the  rear  of  the  slide  is 
in  position  to  function.  '  The  operator  turns  the  small 


engage  the  cam  on  the  chuck  previously  described.  The 
cam  produces  lateral  motion  in  the  tool  C,  which  forms 
the  sinusoidal  waves.  The  cross-slide  is  fed  in  until  the 
stop  is  reached,  which  is  set  for  the  correct  diameter  of 
the  top  and  bottom  of  the  waves.     The  distance  of  the 


OPERATION   8 


N!l.  Cutting  Air  Escape  through  Sinusoidal 


OPERATION      10 

PRESSING  COPPER  BAND  IN  SCORE 


FIG.  16 


A.Einishmdth  and  depth  of  Band  Score       ..„-  „  ..     ^JJJ"**  -L 

B.Undem/t Sides  Nf  2.  flatten  Band into  Score 

C.Turn Sinusoidal haves  FIG.  IT 

FIGS.   16  AND  17.     OPERATIONS  FOR  BANDING 
Fig.  16 — Set-up  for  cutting  the  sinusoidal  ribs.     Fig.  17 — The  banding  operation 


handwheel  E  operating  a  wedge  that  forces  the  under- 
cutting tools  to  the  sides  of  the  groove,  the  width  and 
depth  of  undercut  being  regulated  by  suitable  adjustable 
stop  screws.  The  operator  reverses  the  direction  of  the 
handwheel,  and  the  undercutting  tools  collapse,  per- 
mitting their  withdrawal  from  the  cutting  position. 

The  cross-slide  is  next  fed  in  by  means  of  the  regular 
feed  screw  until  the  yoke  and  the  rollers  I)  connected 
to  the  wave-cutting  tool  C  in  the  front  tool-holding  block 


band  score  from  the  base  of  the  forging  is  permanently 
maintained  by  a  shoulder  in  the  chuck,  which  engages 
the  base  end  of  the  forging.  The  nose  of  the  forging 
is   supported  in   a   ball-bearing   female   center   held   in 


OPERATION     II 

A,  Rough  Turn  Copper  Band 

B,  Finish  Turn  Band 


FIG.    18.      TURNING    THE    COPPER    BAND 

the  turret  hole.  The  tools  are  made  of  tungsten  tool  steel 
and  may  be  ground  upon  their  faces  without  changing 
their  shape.  Soap-water  lubricant  is  employed.  A  speed 
of  35  ft.  per  min.  is  used,  all  feeds  being  made  by  hand. 
Operation  9  consists  in  cutting  air  vents  in  the  si- 
nusoidal ribs  and  fitting  the  copper  band  ready  for  the 


M5.Std. 
Thrtispenh, 


OPERATION     12 


"5 
— UZJ 

FIG.  21.     MACHINING  THE  FUSE  HOLE 


N?l,  Reaming  and  Counterborinq 

Fuse  Hole 
N?Z.  Tapping  flole 


FIG.   20.     COUNTERBORING  AND  TAPPING 


banding  press.  Fig.  17  shows  the  banding  press  and  the 
method  of  performing  this  operation.  In  order  to  shift 
quickly  from  the  6-in.  banding  to  the  3-in.,  special  3-in. 


[53] 


dies  were  made  to  bolt  to  the  regular  6-in.  dies  furnished 
by  the  manufacturers  of  the  banding  press.  A  gage  pres- 
sure of   1000  lb.   is  used,  which  gives  about  40  tons' 


FIG.    23.      LACQUERING   INSIDE   OP   SHELL 

pressure  on  the  band.     Two  squeezes  of  the  press  are 
required. 

Operation  11  consists  in  rough  turning  and  finishing 
the  copper  band.  This  is  performed  in  an  old-style  belt- 
driven  3  x  16  x  20-in.  Pratt  &  Whitney  wire-feed  screw 
machine.  A  special  chuck  and  a  ball-bearing  female 
center,  similar  to  the  ones  described  for  the  Bardons  & 
Oliver  machine,  operation  8,  were  manufactured  for  this 
machine.     A  rigid  tool  block,  holding  the  formed  cutter 


Tapi"Pipt 
A 


A,  Spraying  Manifbld  %/     f 

24,  kt  Nipples  made  fromS 
%* 'Naval  Brass 


with  this  tool,  which  cuts  full  width  and  the  exact  contour 
of  the  band.  A  similar  tool  block  is  bolted  tc  the  tool 
slide  at  the  rear  and  holds  the  tool  B.     The  line  of  cut 

of  this  tool  is  tangent 
to  the  perimeter  of  the 
band  and  is  set  at  the 
correct  height  for 
shaving  the  diameter 
to  exact  size.  The  cut- 
ting tools  are  made  of 
tungsten  special  steel, 
are  interchangeable 
and  may  be  ground  on 
their  faces  without 
changing  their  shapes. 
The  speed  is  40  ft.  per 
min.  The  feed  is  reg- 
ulated by  hand.  The 
lubricant  is  soap- 
water  compound.  Fig. 
19  shows  the  machine 
in  operation.  The  ra- 
dial drill  used  for  oper- 
ation 1  is  also  equip- 
ped for  performing 
operation  12.  The 
shell  is  held  in  a  three-jaw  universal  lathe  chuck 
mounted  in  a  cast-iron  elevating  stand  that  is  bolted  to 
the  drilling-machine  table,  as  shown  in  Fig.  20  and  in 
detail  in  Fig.  21.  The  bottom  of  the  stand  has  a  female 
center  hole  in  which  the  point  of  the  shell  rests.  The 
jaws  of  the  chuck  grip  the  shell  between  the  copper  band 
and  the  base.  A  swing  leaf  that  carries  a  hardened  bush- 
ing is  moved  to  a  permanent  stop  and  locked  in  place  by 
ally  nut.  A  counterbore,  the  body  of  which  fits  the  hard- 
ened bushing,  is  fed  down  to  the  work  by  means  of  the 
hand  lever. 

The  pilot  end  reams  the  fuse  hole  to  the  correct  tapping 
size,  and  the  recess  is  counterbored  to  the  correct  diam- 
eter and  depth  for  the  flange  on  the  fuse.  The  shank 
of  the  counterbore  fits  in  the  drill  spindle  and  is  easily 
removed.  The  speed  for  counterboring  is  100  r.p.m. 
Soap  and  water  compound  lubricant  is  used.  The 
counterbore  tool  is  removed,  and  the  tap  and  socket  are 
inserted  in  the  drill  spindle.  The  swing  leaf  is  moved 
to  one  side,  and  the  pilot  at  the  end  of  the  tap  is  entered 
in  the  reamed  fuse  hole,  thus  assuring  that  the  threads 
will  be  cut  concentric  with  the  base.  The  tap  is  run 
at  30  r.p.m.,  with  pure  lard  oil  as  a  cutting  lubricant. 


B,  3"She//Tray 

C,  Hanger  for  fray 


PIG.    22.      DETAILS   OP    SHELL-HOLDING   TRAY 

A,  Fig.  18,  is  fastened  to  the  front  end  of  the  cross-slide. 
The  line  of  travel  of  the  tool  A  is  in  line  Avith  the  center 
of  the  forging,  the  final  depth  of  cut  being  regulated  by 
a  permanent  stop  to  the  slide.    The  roughing  out  is  made 


FIG.    19.      TURNING   BAND 


[54] 


The  washing  and  lacquering  are  done  in  operation  13. 
The  tanks,  tables  and  benches  made  for  the  6-in.  projec- 
tiles are  used  for  the  3-in.  shell.  Fig.  22  shows  the  tray 
made  to  hold  twelve  3-in.  shells,  each  shell  fitting  over 
a  nozzle  that  thoroughly  washes  the  inside  of  the  shell. 
By  means  of  the  air-hoist  cylinder  the  tray  is  suspended 
in  the  tank  containing  the  washing  solution;  then  it  goes 
to  the  fresh  water  for  rinsing,  and  afterward  to  the  drain 
board.    The  cavity  is  dried  by  compressed  air. 

Lacquering  the  Cavity 

When  the  cavity  is  thoroughly  dry,  the  lacquering  is 
done,  as  shown  in  Fig.  23.  The  funnel  in  the  base  of 
the  cut  shell  has  a  long  spout  that  extends  below  the 
fuse  threads.    A  small  amount  of  lacquer  is  poured  into 


the  cavity  through  the  funnel,  and  the  pipe  rig,  shown 
in  longitudinal  cross-section  of  the  forging,  is  screwed 
into  the  fuse  hole.  When  the  plug  is  screwed  home,  the 
end  of  the  pipe  D  is  immersed  in  the  lacquer  previously 
poured  in,  just  clear  of  the  cavity  point.  The  compressed- 
air  pipe  is  connected  to  B,  which  throws  the  lacquer  out 
against  the  inner  walls  of  the  shell,  the  excess  escaping 
by  the  discharge  pipe  A.  At  E  may  be  seen  a  shell 
that  was  cut  to  determine  how  well  the  surface  was 
covered;  no  bare  spots  could  be  found. 

The  fuse  hole  is  closed  by  waste  or  a  fuse  plug,  and 
the  projectile  is  painted  on  a  turntable.  The  shells  are 
then  sent  to  the  magazine  for  loading  and  stowing,  ready 
for  issue  to  the  service  as  acquired. 


[55] 


United  States  Common  Shrapnel  and  Common 
Steel  Shells,  3.8,  4.7  and  6  In.* 


The  following  specifications  and  operation  lists  for  the 
different  projectiles  shown,  taken  together  with  those  al- 
ready published  for  the  3-in.  sizes,  will  give  manufac- 
turers and  shopmen  something  definite  to  work  from  in 
deciding  on  the  capacity  of  their  shops  in  the  production 
of  munitions  of  this  character. 

The  3.8-In.  Common  Shrapnel  (30  Lb.) 

Fig.  1  shows  the  dimensioned  forging  for  the  3.8-in. 
common  shrapnel ;  Fig.  2  is  the  dimensioned  finished  case, 
while  Fig.  3  illustrates  the  complete  projectile. 

Operations  on  the  Case  (Forging) 
operation  1.    centering 

Tools  and  Fixtures — No.  42  combination  center  drill;  chuck 
and  arbor. 

OPERATION   2.      TURN  BODY 

Tools  and  Fixtures — Special  arbor;  right-hand  lathe  turn- 
ing tool  and  arbor  press.  Gages — Combination  maximum  and 
minimum  snap  for  diameter  of  body;  maximum  and  minimum 
ring  rear  of  band;  length  from  base  to  bourrelet. 

OPERATION  3.     FINISH  EXTERIOR 

Tools  and  Fixtures — Set  of  eight  chuck  pads;  facing  tool; 
circular  form  tool;  circular  form  tool  holder;  knurling  tool; 
knurling-tool     holder.       Gages — Combination     minimum     and 


maximum  band  seat;  maximum  and  minimum  width  and 
depth  of  band  seat;  position  of  band  seat  and  grooves;  thick- 
ness of  base  and  test  piece;  length  over  all. 

OPERATION  4.  FINISH  INTERIOR,  ROUGH-TURN 
BOURRELET,  ROUGH-TURN  OGIVE 
Tools — Set  of  chuck  pads;  diaphragm-seat  finishing  cutter; 
diaphragm-seat  cutter  bar;  tap;  ogive  cutter;  right-hand 
rough-turning  tool.  Gages — Maximum  and  minimum  diameter 
of  diaphragm  seat;  depth  of  diaphragm  seat;  maximum  and 
minimum  thread  plug  gage;  maximum  and  minimum  diameter 
of  powder  chamber;  maximum  and  minimum  root  of  thread. 


OPERATION  5. 
Tools — Special  wrench. 


ASSEMBLE  HEADS 


♦Copyright,  1917,  McGraw-Hill  Publishing  Co.,  Inc. 


OPERATION  6.     FINISH-TURN  HEAD  AND  BOURRELET 
Tools — Right-hand  turning  tool;  form;  rear  of  cross-slide 
follower _;    special   chuck;    revolving   center.     Gages — maximum 
and  minimum  ring  gage;  diameter  of  bourrelet;  ogive  profile 
gage;  diameter  of  nose  thread  plug. 

OPERATION    7.      DISASSEMBLE    HEAD 
Tools — Special  wrench. 

OPERATION  8.     HYDRAULIC  TEST 
Special  Fixtures — Test  fixture. 

OPERATION  9.     ASSEMBLE  BAND 
Equipment  Used — Set  of  banding  dies;  pair  of  tongs;   gas 
furnace. 

OPERATION  10.     TURN  BANDS 
Tools — Special  chuck;  steadyrest;  form;  rear  of  cross-slide 
follower;    facing    tool;    band-turning   tool;    special    stop;    tool- 
post  holder  rear  of  cross-slide.     Gages — Maximum  and  mini- 
mum ring  gage  diameter  of  band;  profile  and  position  of  band. 

OPERATION  11.     WASH  IN  HOT  SODA 
Equipment  Used — Pair  of  tongs. 

OPERATION  12.     PAINT  INSIDE 


Stamp  with  Q/25 Letters  and  figures, 
_J^nd/lmmuniti^Lot^~^^^^0/§tSO/5''.O5ho^ 

H  I  L.VUiL?7/Sm& 


mi 


S&i 


$>    ^n} 


m 


W5'' 


Head  Filler 
RESIN 


Matrix 
RESIN  AND  PURE  WHITE  COMMERCIAL  Stopper 

NAPTHALENE(Not  Crystalled).        .-GUN  COTTON ) 


_JS"/^-/f\<—-  --I0.I2- 

Slightly  moisten  these  Joints  with  Cosmokne 
Assembly 


ScoresJ2 Per  Inch 

Y=l8hJrlnchUS 
Sta!  Thread 


-  _>|  Correcting DefectNe^-238 "tQ005 
Shnapnel  Cases 


Washer  ,^>, 
STEEL-WS^ 


\^STEEL,finish/m^ 


a 


Lock  Pin 

§*&  3%  X-MRerlnch.  US    STEEL,FinishJtQ005" 
Std.  Thread 


Diaphragm 

STEEL,t(W5" 


Retainer 

BRASS 


Inner  Tube 

COPPER  mi" 


Form  of  Scores  $''$£ 

->\0S4\<---+(2W' 

o 

Ball 


czn 


m 


tr.z\ 


Band 

COPPER 


1 

Jt 

7> 


FIG.  2 


[56] 


we 


Diaphragm 

5TEELia005" 


^y\~,ri> assembling    <* 
4#       *  hC°Se  ^  Locking  Rn 

Head 
ST£EL,FinishpQOl" 


0:377%™ 
STZLfinishfim"  ]nw/%F$a° 


Tube 


[57] 


Operations  on  the  Head 

After  the  head  has  been  rough-machined,  it  is  assem- 
bled to  the  case,  as  the  fifth  operation  on  the  case.  The 
head  and  bourrelet  are  then  finish-turned. 

OPERATION  1.  MACHINE  FROM  BAR 

Tools  and  Fixtures — Set  of  chuck  pads  and  bushings;  feed 
shell  pads  and  bushings ;  stop ;  twist  drill ;  drill  holder ;  set 
rough  grooving  tools;  set  rough  combination  grooving  tools; 
holder;  set  finish  grooving  tools;  combination  counterbore  and 
reamer;  collapsible  tap  and  chasers;  double-end  fiat  forming 
tool;  cutting-off  tool  and  suitable  holders.  Gages — Length 
and  diameter  of  thread;  length  from  front  to  thread;  inside 
diameter  of  crimping  wall;  maximum  and  minimum  thread 
plug;  depth  of  groove;  length  over  all. 

OPERATION  2.     COUNTERSINKING 

Tools — Chuck;  beveling  tool.     Gages — Diameter  and  profile 
of  fuse-seat  bevel;   minimum  diameter  of  fuse  seat  and   fuse- 
seat  thread. 
OPERATION  3.     THREAD  AND  CRIMP  IN  STEEL  WASHER 

Tools — Chuck  ;  crimping  tool ;  circular  thread  cutter  ;  leader 
and  follower.     Gages — Maximum  and  minimum  thread  ring. 


Inner  Tube 
operation  1.    machine 

Tools — Stop;  60-d'eg.  countersinks;  belling  tool;  chamfering 
tool;  cutoff  tool.  Gages — Combination  length  and  diameter 
of  bell. 

Central  Tube 
operation  1.    machine 

Tools — Reamers  for  inner-tube  seat;  90-deg.  countersinks; 
cutoff  tool;  chamfered  tool.  Gages — Length;  combination 
depth  and  diameter;  inner-tube  seat. 

Washer 
operation  1.    punch 

-Punch    and    die. 

Diaphragm 


Tools- 


OPERATION  1.     DRILL  AND  COUNTERBORE 
Tools — Special    chuck;    twist    drill;    counterbore;    counter- 
sink    and     holders.       Gages — Maximum     and     minimum     plug; 
diameter  of  counterbore;   depth   gage   for  counterbore;   maxi- 
mum and  minimum  ring;  outside  diameter. 


Press  Metafof  Fuse  into 
Notch  for  Locking 


Slightly  moisten 
I  these  Joints  with  Cosrnolene  - 

I 
Y'—208"-^- J"— — >k- 


Assembly 


H~%  IdPerlnchUS. 
r<2H  Sty.  Thread 


>^Q/Efr 


UPerlnchUS^ 
5t'd.  Thread 


Base  Cover 

BRASS 
tQ.QQ5" 


Fuse  Hole  Plug 

DIE  CAST  WHITE  METAL 
NON  CORROSIVE 


FIG.9 


OPERATION    4.      MILL  NOTCHES   IN    HEAD 
Special  Fixtures — Milling  cutter  and  arbor. 
OPERATION  5.     GROOVE  FOR  WATERPROOF  COVER 
Tools — Screw    chuck;    special    lathe    tool.      Gages — Water- 
proof-cover scratch  gage;  position  of  waterproof -cover  groove. 
OPERATION    6.      PAINT    INSIDE    HEAD 
OPERATION  7.     PUT  IN  RETAINER  AND  FILL  HEAD 

OPERATION  8.     CUT  OUT  SURPLUS  RESIN 
Tools — Special   chuck  and   right-hand  side-facing  tool. 
OPERATION    9.    COAT    THREADS    WITH    COSMOLINE 

OPERATION    10.      REASSEMBLE    HEAD    TO    CASE 
Tools — Special  wrench. 

OPERATION  10-A.     INSERT  INNER  TUBE 
Tools — Punch. 

OPERATION    11.      PIN    HEAD    TO    CASE 
Tools — Drill  chuck;  twist  drill;  fixture  for  holding  case. 

operation  12.    final  inspection 
Locking  Pins  (Bar  Stock) 

operation  1.    machine 
Tools — Stop;  cutoff  tool;  form  tool.     Gages — Length. 

Retainer 
operation  1.    machine 

Tools — Stop;   cutoff;   chamfer  tool.     Gages — Length. 


Matrix 

STEEL 
-W" 

OPERATION  2. 

OPERATION  2-A. 

OPERATION 


Fuse  Hole  Plug 

STEEL  OR  BROA/ZE 


HEAT-TREATMENT,  1600  DEG.  F. 
PLACE  IN  COTTONSEED-OIL  BATH 
2-B.      RUMBLE    IN   HOT    SALT    TO 
REMOVE  SCALE 
OPERATION  2-C.      HOT  SALTPETER  BATH,   900   DEG.   F. 
OPERATION  3.     REMOVE  SCALE  FROM  COUNTERBORE 
OPERATION  4.     GRIND  BASE 
OPERATION   5.      PAINT  BASE 
OPERATION  6.     ASSEMBLE  TUBE 
Special   Fixtures — Centering   fixture.     Gages — Length. 

Loading 

operation  1.   insert  diaphragm  in  tube 

operation  2.    fill  case 

operation  3.    compress  balls 

operation  4.    cut  out  surplus  resin 

Tools — Universal  chuck;   steady-rest;   resin   cutter.     Gages 
-Depth. 

The  4.7-In.  Common  Shrapnel  (60  Lb.) 

A  dimensioned  forging  of  the  4.7-in.  common  shrapnel 
is  shown  in  Fig.  4,  and  a  dimensioned  case  is  given  in 
Fig.  5.    The  complete  projectile  is  illustrated  in  Fig.  6. 


[58] 


The  operations,  tools  and  gages  are  of  practically  the  same 
type  as  for  the  3.8-in.  size. 

The  6-In.  Common  Shkapnel  (120  Lb.) 

In  Fig.  7  is  a  dimensioned  forging  of  the  6-in.  common 
shrapnel.  A  dimensioned  case  is  shown  in  Fig,  8,  and 
the  complete  projectile  is  illustrated  in  Fig.  9.  The  oper- 
ations, tools  and  gages  are  of  the  same  type  as  for  the 
preceding  sizes. 

The  3.8-In.  Common  Steel  Shell,  Model  1905 

Fig.  10  shows  a  dimensioned  forging  of  the  3.8-in. 
common  steel  shell,  and  a  dimensioned  case  is  presented 


form  for  point;  follower.  Gages — Combination  snap  maximum 
and  minimum  rough  diameter  of  bourrelet;  projectile  profile; 
profile  of  point. 

OPERATION  4.     MILL.  THREADS  IN  BASE 

Tools — Thread  milling  cutter;  arbor;  spring  chuck.  Gages 
— Maximum  thread  plug;  minimum  thread  plug  and  eccentric- 
ity of  counterbore. 

OPERATION   5.     MACHINE  BASE-COVER  GROOVES 

Tools — Toolholder  (fixed  spindle);  four  roughing  tools; 
toolholder;  fixture  on  cross-slide  with  finishing  tools;  finishing 
toolholder  and  two  tools.  Gages — Inside  diameter  working 
gage;  diameter  depth  and  width. 

OPERATION  6.     HEAT-TREATMENT 
(A)  Heat  in  furnace;   (B)  cottonseed-oil  bath;   (C)  heat  in 
lead  furnace. 

OPERATION  7.     FINISH-GRIND  BOURRELET 
Tools — Electric  grinder;  special  chuck;  steady-rest.     Gages 
— Maximum  and  minimum  ring  diameter  of  bourrelet. 

OPERATION  8.     ASSEMBLE  BANDS 
Tools — Banding  dies;  tongs;  gas  furnace. 


lOThd,perlnch,LII,US.5td    ^-a^^^ g^ 

|<- -14.135  ±0.12"- -— 

Finish  outside  f.  Rough  inside  except  where  marked  f  Coat  inside  with  non  -acid paint  except  nhere  marked  X 

.   F0R6ED  STEEL  (±0.0l") 
l2Thds.perlnch,LettHand,U.S.Std.       o^'OOO"-..  shell 

WThds perlnch.UfiHand,  USStd./^^qO?  g»| .^r^t  „;th  Cosmokne before  assembling 


\<-i.oo  ->\  yo.2 

12  Threads  per  Inch,  Lett  Hand,  USStandard-. 


J  notches  equally  spaced 
Force  fuse  metal  into  notches 
for  locking 

Coat  front  end  with  non- acid  paint 
Base  Plug 


a  H-  K Jl        r  I     w    1-UKOtU 

Zaooo^08^'5™     » 

02  OWf  \*-l.5"W3"A  FinishftO.01 


^ 


0.55-A  p-ass--* 

U:-!2".~>\ 


Weight  0.791b  Steel 
»■    0.86  lb.  Bronze 


f0.8"AVai* 

\<-f.45"-A 


Die  cast  (White  Metal)  non-corrosive,  tOOl 
■Fuse-Hole  Plug 

"fig.ii 


in  Fig.  11.     The  operations  are  practically  the  same  as 
for  the  4.7-in.  shell. 

The  4.7-In.  Common  Steel  Shell,  Model  of  1905 

From  Fig.  12  may  be  obtained  the  .dimensions  of  the 
forging  for  the  4.7-in.  common  steel  shell,  while  Fig.  13 
shows  a  dimensioned  case. 

OPERATION  1.   ROUGH-TURN  BODY 

Tools — Universal  chuck;  revolving  center;  right-hand  lathe 
turning  tool. 

OPERATION  2.  MACHINE  INTERIOR  AND  EXTERIOR  OF 
BASE  AND  FINISH-TURN  BODY 
Tools — Chuck  pads;  combination  counterbore  and  reamer; 
recessing  tool;  circular  form  tool;  knurling  tool;  right-hand 
lathe  turning  tool  and  holders.  Gages — Depth  of  cavity  and 
warp;  base  plug  flange  seat;  maximum  and  minimum  ring 
diameter  rear  of  band;  combination  snap  diameter  band  seat; 
position  of  band  seat  and  crimping  grooves;  combination  snap 
diameter  of  body;  position  of  grooves;  length  of  base  to 
bourrelet. 

OPERATION    3.      FINISH-TURN   POINT   AND    ROUGH-TURN 
BOURRELET 
Tools — Special  chuck;  steady-rest;  left-hand  lathe  turning 
tool;  former  rear  of  cross-slide;   extension  bracket  and  roller; 


STEEL  OR  BRONZE 

Fuse -Hole  Plug 
OPERATION  9.     TURN  BANDS 


Tools — Special  chuck;  steady-rest;  right-hand  side-facing 
tools;  band-turning  tool;  special  stop;  form  and  follower  rear 
of  cross-slide.  Gages — Maximum  and  minimum  ring  diameter 
of  band;  position  and  profile  of  band. 

OPERATION  10.     HYDRAULIC  TEST 
Equipment    Used — 1500-ton    heading    press    with    pressure 
pump;  testing  fixture;  triplex  chain  drop. 

Base  Plugs 
operation  1.    machine  from  bar 

Tools — Stock  stop;  two  twist  drills;  two  drill  holders;  com- 
bination floating  counterbore  and  reamer;  forming  tool;  facing 
tool;  cutting-off  tool;  chuck  pads;  feeding  finger  pads  and 
toolholders.  Gages — Maximum  and  minimum  plug  diameter 
\>f  small  hole;  depth  and  diameter  of  counterbore;  maximum 
and  minimum  diameter  of  flange;  maximum  and  minimum  snap 
diameter  of  thread;  overall  length  of  base;  plug  and  width  of 
flange;  length  of  thread. 

OPERATION    2.      MILLING    INTERNAL    THREAD 

Tools — Combination  milling  arbor  and  cutter;  spring  chuck. 
Gages — Maximum  and  minimum  thread  plug. 

OPERATION  3.   CUTTING  EXTERNAL  THREAD  ON 
TURRET  LATHE 

Tools — Threading  attachment;  chuck;  screw  for  chuck; 
circular  thread  cutter;  chamfering  tool.  Gages — Maximum 
and  minimum  thread   ring. 


[59] 


STEEL 

u - 


.  vo45"mk 

"Tor  Comb.  Center  Drill 
I 


■-I9.6+Q4-QI- 

ne.  12 


|<-  •y4454tQ0l" -^ -5-00*03" *l ' 


h- 07S-'- 

h— W — H 


1  QI5y--Q45"~"->\  QI5'Y 


Stamp  with  QI25  Letters' and  Figures 
FA.  and  Ammunition  Lot  Na. .  „.*..* 
Jfflfiy*. ^ 

L^-I.OSl8Mn  l/SStdM  LH 


=•1 
Section  of  Band 

COPPEP 


p?  7' 

*'  ^\4 Slots  equally 
spaced,W49eep 


i.9"-^^oresimrIn  m'@9Z5Jm*Q&V^A<%7Wr 


Three  Notches 

equally  spaced-    8  Per  In,  USStd.Thd.LH 

0"  i 


■//mm 


;,-9.94" 


J 


vr  "»• i' -*r 685*m *■. 

-18.521015 | -| - H 

i  Capacity  with  Base  Plug  in  place  70.78(70.98)  Culn. 
"       "       Fuse     "    "     667Cu.In. 
Finish  outside/.  Rough  inside  except  where 
marked /.Coat  inside  with  Nonacid  Paint 
except  where  marked  /  -0.01" 


Band 

COPPER 


■*V0.I5\ 
'y-i?\0.4^Q9''^ 


■Coat  this  end  with 
Non-acid  taint 

Base  Plug 

STEELFmish/m 


X*l2ferInUS.Sfd.Th'd.LH 

~>\Y-0/& 


\<--l45'--A 


FIG.I3 


Fuse  Hole  Plug 

WROUGHT  IRON  OR  BRONZE 
Finish/A 


A. 

V~I0?"A  •H£5*"-//-'->l 

te*  k I4?-M 

Fuse  Hole  Plug 

DIECAST  WHITE  METAL  (Non-corrosive) 


Base  Plug 

FOROEDSTEELFinish 


{■■or. 

Fuse  Hole  Plug 

WR0UGHTIR0N 
Finish/100/" 


z- 

[ikiSJ 

%■ 

i_ 

r^rf" 

ki?//k*l 


FIG.  15 


V—i?'--^  Woz" 

Fuse  Hole  Plug 

DIE  CAST  WHITE  METAL 
Non-corrosive±Q0l " 


[60] 


OPERATION  3.     CUTTING  EXTERNAL  THREAD  ON  The  6_In<   COMMON  STEEL  SHELL 

Tools — Thread    milling    cutter;    arbor    for    cutter;    spring  a    flimprminnprl   poop  nf  thp   fi-in     pmnmnn   <stpp1    «Vip11   ic 

chuck.    Gages— Maximum  and  minimum  thread.  A  dimensioned  case  oi  me  o-m.  common  steei  sneii  IS 

operation  4.    notch  base  shown  in  Fig.  14.    The  operations  on  this  shell  are  prac- 

Toois— Fixture;  milling  cutter;  arbor.  tically  the  same  as  for  the  4.7-in.  size. 

OPERATION  5.     MILLING  wrench  slots  j 


[61] 


Ammunition  tor 
American  Merchantmen 


ByLieutA.  G.Dibvell 


SYNOPSIS — The  necessity  that  has  forced  us  to  either  arm  our  merchantmen  or  give  up  our  rights 
to  sail  the  seas  makes  necessary  the  manufacture  of  shells  for  the  guns  to  be  used  on  merchantmen. 
The  sinking  of  the  numerous  vessels  without  warning  of  any  kind  emphasizes  the  necessity  for  arms 
and  ammunition  with  which  to  protect  our  commerce  and  the  lives  of  American  seamen.  This  article 
gives  in  detail  the  methods  used  by  the  navy  yard  at  Puget  Sound  for  making  6-in.  common  naval  shells. 


Owing  to  the  great  demand  made  upon  this  country, 
many  shops  are  now  thoroughly  familiar  with  the  process 
of  manufacturing  British,  French  and  Eussian  shells. 
The  United  States  Navy  pro- 
jectiles differ  radically  from 
the  army  shells  of  foreign 
countries  and  require  a  de- 
parture from  the  methods  of 
manufacture  of  foreign  shells. 
As  the  time  for  shops  to  get 
started  on  this  work  may  be 
short  in  case  of  war,  it  is  be- 
lieved that  a  description  of 
a  successful  method  of  ma- 
chining the  navy  projectiles 
will  make  it  possible  for  con- 
tractors to  equip  their  ma- 
chines by  the  time  forgings 
can  be  obtained.  Further- 
more, the  ideas  here  set  forth 
may  enable  mechanics  in  the 
United  States  to  improve  on 
this  method,  thereby  decreas- 
ing the   cost  and  increasing 

the  output.  There  are  three  essentials  in  the  machining  of 
projectiles :  ( 1 )  They  must  be  of  a  certain  weight  within  a 
very  small  tolerance,  because  a  standard  weight,  or  charge, 


FIG.  1.     ROUGH-FORGING  AND  FINISHED  UNITED 
STATES  NAVY    6-IN.    COMMON   PROJECTILE 


♦United   States   Navy,   Submarine   Division. 


of  powder  is  used  and  undue  variation  in  the  weight  of 
the  projectiles  affects  the  range;  (2)  the  center  of  gravity 
must  be  maintained  or  the  projectile  will  "tumble"  in 

flight;  (3)  the  projectile 
must  be  concentric  or  it  will 
give  an  erratic  flight,  causing 
wide  dispersion.  These  bal- 
listic qualities  a  shell  must 
have;  but  just  how  to  ob- 
tain them  and  keep  within  all 
the  small  tolerances  allowed 
in  the  dimensions  is  the  me- 
chanical problem  to  be  solved. 
From  experience  gained  at 
the  Puget  Sound  navy  yard, 
and  in  other  shops  visited,  it 
may  be  stated  as  a  general 
rule  that  the  ordinary  three- 
and  four- jawed  lathe  chucks 
cannot  be  successfully  em- 
ployed in  the  manufacture  of 
shells.  Draw-in,  or  pot  chucks, 
collet  chucks  and  expanding 
mandrels  must  be  used.  To 
save  the  cost  of  handling,  as  many  operations  as  possible 
should  be  performed  at  one  chucking;  and  where  engine 
lathes  are  employed  turret  heads  should  be  fitted  to  the 
crossfeed. 


[62] 


Fig.  1  gives  the  dimensions  of  the  rough  forging  fur- 
nished the  navy  yard,  hut  not  the  dimensions  of  the  fin- 
ished projectile.  It  was  assumed  that  the  steel  billets 
would  be  punched 
in  the  forming 
dies  at  one  stroke. 
In  that  case  allow- 
ance  must  be 
made  for  the 
punch  running 
out  of  true  in  a 
great  many  forg- 
ings.  Fig.  2  shows 
the  centering  and 
gaging  machine. 
This  machine 
serves  two  pur- 
poses :  First,  cen- 
tering the  outside 
of  the  forging 
true  with  the  cav- 


forging  is  pierced  too  much  out  of  center  or  flat  on  the 
radius,  it  is  marked  and  no  machine  work  is  wasted  on  it. 
The   machine   consists   of   a    cast-steel   stand   with   two 


FIGS.    2   TO   4.    CENTERING   GAGE   AND   THE   METHOD   OP  DRILLING  THE  CENTER 
Fig-.  2 — View  of  centering  and  gaging  rig,  operation  1.     Fig.  3— Six:inch  projectile   forging   in   centering  and   gaging  rig. 


Fig.   4 — Drilling  center  in  6-in.  forging,   operation   1 


ity, 

ing 
ing 


for  rough-turning  the  outside,  and  second,  determin- 
whether  or  not  there  is  sufficient  stock  in  the  forg- 
for  finishing.     If  insufficient  stock  is  found,  or  the 


columns  between  which  the  forging  is  placed  for  center- 
ing and  gaging.  On  top  of  the  column  is  a  swinging  arm 
secured  by  a  handle  nut,  containing  the  centering  bush- 
ing. The  stop  on  the  back  allows  the  spindle  to  tilt  about 
65  deg.  for  slipping  the  rough  forging  over  the  spindle 


fig.  5. 


EXPANDING  MANDREL  FOR  HAMILTON  LATHE, 
OPERATION  2 


FIG.   6.    RADIUS-TURNING  ATTACHMENT  FOR   HAMILTON 
LATHE,   OPERATION  2 

The  weight  of  the  shell  on  the  cone  forces  the  three 
rollers  out  against  the  base  of  the  forging,  firmly  holding 
the  forging  true  with  the  cavity.  The  forging  is  thrown 
back  into  the  frame  and  the  top  plate  closed.  The  forg- 
ing is  removed  by  the  forked  handle  shown. 


[63] 


A  later  development  was  fitted  to  offset  the  forgings 
when  too  much  out  of  center  for  the  machine.  This  con- 
sists of  handwheels  on  threaded  stems  operating  the  base 

of  the  spindle  and 
giving  an  offset  of 
■£$  in.  Each  forg- 
ing is  revolved  on 


FIG.  7.    ROUGH-TURNING  6-IN.  FORGING,  OPERATION  2 

the  centering  spindle  while  the  movable  indicator  pins 
are  held  against  the  forging.  Should  the  stock  pins,  Figs. 
2  and  3,  show  insufficient  stock  for  finishing,  the  lines  on 
the  indicator  pins  pass  beyond  the  es- 
tablished marks.  If  the  forging  is 
good,  it  is  center-punched  through  the 
bushing,  as  shown  in  Fig.  3,  and  the 
bench  mark  is  established  on  the  base 
of  .the  forging.  The  forging  is  then 
removed  and  the  center  drilled  in  a 
radial  drill  press,  Fig.  4.  The  bush- 
ing in  the  swing  lever  has  recently 
been  enlarged,  and  the  base  of  the 
casting  is  bolted  to  the  press  table  so 
that  the  drilling  is  done  without  re- 
moving the  forging  from  the  center- 
ing machine.  This  operation  has  been 
found  necessary,  as  the  points  of  many 
forgings  dropped  in  cooling.  Foi 
operation  2,  an  old  32-in.  by  8-ft. 
Hamilton  engine  lathe  was  fitted  with 
an  expanding  mandrel  and  a  radius- 
turning  attachment.  The  outside  hav- 
ing been  centered  with  the  cavity,  the  forging  may  be  held 
on  a  mandrel  for  rough-turning.  The  mandrel  was  design- 


be  rough-turned  the  entire  length  concentric  with  the  cav- 
ity. The  mandrel  is  made  of  cast  steel  and  fits  over  the 
lathe  spindle.  The  forging  is  gripped  by  three  dog  wedges 
of  tool  steel,  shown  at  A  in  Fig.  5,  which  are  held  in  place 
by  pins  and  springs,  shown  at  B  and  0.  These  dog 
wedges  are  forced  out  by  the  medium-steel  taper  spindle 
shown.  The  rod  screwed  into  the  taper  spindle  runs 
through  the  hollow  spindle  of  the  lathe  and  is  operated  by 
a  handwheel.  The  grip  is  over  a  length  of  3  in.,  and  the 
shell  is  further  supported  by  the  tailstock  in  the  center 
drilled  in  operation  1. 

In  order  to  obtain  a  heavy  cut  and  prevent  chatter- 
ing of  the  tool  a  positive  radius-turning  attachment  was 
made  for  the  roughing  machine,  in  accordance  with  Figs. 
6  and  7.  The  frame  consists  of  two  arms  of  cast  iron 
secured  to  the  back  of  the  lathe  bed,  shown  at  A.  The 
radius  arm  B  is  of  medium  steel  on  a  radius  of  45.5  in. 
and  is  secured  to  the  tool  carriage  by  a  composition  G- 
bolt.  In  order  to  remove  the  metal  on  the  roughing  cut 
as  quickly  as  possible,  two  tools  were 
fitted;  one  to  take  the  straight  cut 
and  the  other  to  begin  at  the  bour- 
relet  and  take  the  radius.  Marks 
established    on    the    lathe    face- 


ed  to  grip  the  inside  of  the  forging  firmly,  so  that  it  would  ' 


PIG.  9.    GISHOLT  LATHE  PITTED  FOR  PERFORMING  OPERATION  3 

plate  and  a  carriage  indicator  is  used  for  setting  each 
forging  correctly.  A  shell  is  accurately  gaged  from 
this  machine  once  each  day  to  determine  whether  the 
tools  are  properly  set  and  that  the  forgings  are  leav- 
ing the  machine  in  accordance  with  instructions. 

The  forging  is  chucked  on  an  expanding  mandrel  and 
accurately  set  with  the  tram  in  the  bench  mark  and  the 
established  mark  on  the  mandrel  nut.  The  center  line  of 
the  radius-turning  bar  is  set  7.02  in.  from  the  bench  mark 
established  in  operation  1 ;  at  this  point  the  indicator  on 
the  lathe  carriage  coincides  with  the  established  gage 
on  the  lathe.    With  the  carriage  set  in  this  position,  the 


FIG.   8.    DETAILS   OF  BORING  BARS  AND   BORING   HEADS 
FOR    GISHOLT    LATHE,    OPERATION    3 


FIG.    10.    CUTTING   AIR    VENTS    IN   SINUSOIDAL    RIBS, 
OPERATION  4 


[64] 


radius-turning  ^ool  is  accurately  set  with  gages.  The  tool 
for  turning  the  straight  body  is  set  10.5  in.  behind  the 
radius-turning  tool.  The  base  of  the  forging  is  then 
faced  off  to  the  bench  mark. 

The  f  orgings  are  6|  in.  in  diameter  in  the  'rough,  and 
to  turn  to  6Tyn.  requires  a  cut  of  ■£?  in.  on  a  side.  This 
gives  TV  in.  to  finish.  No  cutting  compound  is  used  in 
this  operation.  The  cutting  tools  are  made  of  £  x  l-|-in. 
tungsten  tool  steel.  A  speed  of  47  ft.  per  min.  with  a 
feed  of  V28  in.  is  used,  and  it  is  necessary  to  sharpen  tools 
about  every  sixth  shell.  This  operation  is  also  shown  in 
Fig.  7,  which  is  a  view  taken  from  the  back  of  the 
lathe  to  show  the  radius  attachment. 

The  outside  having  been  rough-machined  concentric 
with  the  cavity,  the  forging  can  now  be  chucked  in  a 
universal  pot-chuck 
for  boring  the  cav- 
ity. Gisholt  turret 
lathes  were  the 
most  available  for 
the  boring,  opera- 
tion 3,  a  universal 
chuck,  bolted  to  the 
faceplate  flange  be- 
ing used.  This  is  a 
draw-in  chuck  with 
a  20-in.  wheel,  the 
collet  being  made 
in  six  segments 
carefully  machined. 
The  segments  are 
separated  by  small 
springs,  which  release  the  forging  when  the  nut  is  backed 
off  the  taper. 

Fig.  8  shows  the  special  boring  bars  and  cutting  heads 
for  the  Gisholt  turret  lathe.  The  straight  head  A  car- 
ries the  cutting  tools  for  boring,  these  being  made  of  -J-in. 
square  tungsten  tool  steel.  Two  heads  were  made  for 
each  bar,  so  that  the  cutting  tools  could  be  changed 


FIG.   11.     DETAILS  OP   PLATE 


FIG.   13. 


SIX-INCH  PROJECTILE  FORGING  IN  BANDING 
PRESS,  OPERATION  5 


and  a  reserve  head  remain  always  available.  The  rough- 
boring  bar  removes  g^  in.  of  metal,  finishing  a  hole  to 
3§£  in.  and  leaving  -fa  in.  to  be  removed  by  the  finish- 
ing tool.  The  f orgings  are  received  with  an  inside  diam- 
eter of  3|  in.  and  must  be  finished  to  an  inside  diam- 
eter of  4  inches. 

The  roughing  radius  head  is  shown  at  B.  The  cutters 
are  made  of  £  x  £-in.  and  |  x  1-in.  tungsten  tool  steel  and 
the  lengths  of  cutters  vary  as  shown  in  the  illustration. 
These   cutters   are   designed   to   remove    the   maximum 


amount  of  metal  that  the  machine  will  pull.  The  finish- 
ing head  is  shown  at  C  and  the  finish  cutters  at  D.  These 
cutters  leave  a  clean,  smooth  surface.  The  point  of  the 
shell  is  finished  by  the  cutter  E. 

The  Cutting  Compound 
In  order  to  obtain  cutting  compound  on  the  point  of 
the  cutting  tool  f-in.  holes  (not  shown  in  the  drawing) 
were  drilled  through  the  bars,  the  discharge  opening  be- 


FIG.    12.    DETAILS    OF    MANDREL    AND    EJECTOR    FOR 
BANDING    PRESS,    OPERATION    5 

ing  in  the  heads.  A  plug  was  fitted  to  each  bar  and  the 
flexible  hose  connection  made  by  means  of  a  bayonet  joint. 
This  is  shown  in  Fig.  9.  The  cutting  compound  is  a 
mixture  of  2  lb.  of  borax  dissolved  in  10  gal.  of  boiling 
water,  to  which  is  added  2  gal.  of  boiling  lard  oil.  The 
tools  require  changing  about  once  a  day  or  about  every 
tenth  forging.  Each  bar  is  fitted  with  an  independent 
stop  and  these  are  tested  and  adjusted  once  daily.     A 

boring  speed  of  30  ft.  per 
min.  with  a  feed  of  1/40 
in.  per  revolution  is  used. 
In  addition  to  the  boring 
operations  a  turret  head 
is  fitted  on  the  tool  car- 
riage of  these  lathes  to 
carry  tools  for  cutting 
the  copper  band  groove, 
undercutting,  cutting  the 
sinusoidal  rib  and  round- 
ing the  base.  The  band 
score  is  first  rough-cut 
to  a  diameter  of  5.8  in.; 
then  the  sinusoidal  cam 
is  thrown  in  and  the 
groove  finished  to  5.7  in. 
at  the  bottom.  The 
undercutting  is  done 
next  and  finally  the  base 
of  the  shell  is  rounded. 
This  requires  four  tools 
on  the  turret  head  of  the 
tool  carriage,  these  oper- 
ations being  completed 
during  the  boring.  The 
sinusoidal  rib-cutting  cam  arrangement  is  shown  in  Fig. 
9.  The  cast-iron  camplate  A  is  bolted  to  the  face- 
plate of  the  lathe,  and  the  cast-iron  plate  B  is  fast- 
ened to  the  lathe  carriage.    The  medium-steel  arm  C  con- 


F1G.   14.    MARKING  BASE, 
OPERATION  6 


[65] 


nects  the  two  pieces,  the  cam  motion  being  positive,  by 
means  of  casehardened  rollers  on  each  side  of  the  cam- 
plate. 

Operation  4  consists  in  cutting  air  vents  in  the  sinusoi- 
dal ribs.  Fig.  10.     The  copper  band  is  slipped  over  the 


in  about  0.015  in.  in  banding.  To  prevent  this  a  special 
mandrel  was  designed,  Figs.  11,  12  and  13.  A  large 
hexagonal  |-in.  plate  A,  Fig.  11,  was  fitted  inside  of  the 
rams  of  the  press.  Through  this  plate  a  hole  was  cut  7 
in.  in  diameter.     Underneath  this  plate  are  fitted  two 


12 Threads 


FIGS.  15  TO  17.     GAGES  AND  METHOD  OF  WEIGHING   FOR  OPERATION    ? 
Fig.    15 — Measure    weight    and    gage,    operation    7.      Fig.    16 — Details  of  gage  for  operation  7.     Fig.  17 — Depth  gage  used 

in   operation   7   and   gages  for  base  and  base   plug 


base  and  struck  a  blow  with  a  wooden  mallet  to  seat  it  in 
the  groove,  operation  5. 

Experiments  conducted  after  the  arrival  of  the  banding 
press  indicated  that  the  base  of  the  forging  was  crushed 


zzzr 


Section 
X-Y 


FIG.    18.    EXPANDING    MANDREL    FITTED    TO    LE    BLOND 
ENGINE  LATHES  FOR  FINISH-TURNING,  OPERATION  8 


hinged  plates  B  with  lugs  sliding  in  slots  cut  in  the  upper 
plate  A.  The  diameter  of  the  plate  B  is  5f  in.  A 
spring  slips  over  the  lugs  to  hold  the  plate  in  place  while 
the  shell  is  being  put  in  and  taken  out  of  the  press. 
The  spring  and  the  lugs  are  better  shown  in  Fig.  13. 

In  Fig.  12,  A  is  an  expanding  mandrel  of  medium  steel 
which  slips  into  the  base  of  the  forging  and  is  forced 
out  against  the  inner  walls  by  the  taper  spindle  B.     C 


FIG.  19.    GAGE  FOR  DETERMINING  ECCENTRICITY  OF 
WALLS,  OPERATION  8 

is  a  screw  bushing  which  screws  into  the  telescopic 
sleeve  D.  The  guide  for  the  mandrel  is  operated  by  a 
hand  lever.  This  guide  works  in  the  inner  sleeve  E 
of  the  telescope.  The  action  is  as  follows :  The  plates  B 
are  closed  and  locked  by  the  spring.  The  forging  is  set 
on  its  base  on  this  plate  and  the  mandrel  handle  lifted, 
forcing   the   mandrel    into   the    cavity.      The    plates    B 


[66] 


are  thrown  out  and  the  forging  lowered  to  the  handing- 
position,  which  is  determined  by  a  stop.  The  band  is 
given  four  squeezes  of  the  press,  the  forging  being  slightly 


FIG.    20.    FINISH-TURNING,    SHOWING    RADIUS 
ATTACHMENT,  OPERATION   8 

rotated  after  each  squeeze.  A  gage  pressure  of  2500  lb. 
is  applied,  which  gives  a  total  pressure  of  100  tons  on 
the  copper  band.  The  hand  lever  is  again  lifted,  the 
plates  B  thrown  under  the  base  of  the 
forging,  and  the  mandrel  withdrawn. 
The  device  for  marking  the  base,  oper- 
ation 6,  consists  of  a  cast-iron  base  to 
which  are  secured  the  two  uprights, 
Fig.  14.  The  dieplate  containing  the 
letter  die  slides  up  and  down  on  the 
uprights.  The  dieplate  is  secured  to 
the  base  of  the  shell  by  means  of  a  set- 
screw.  The  counterweights  lift  the 
die  and  plate  after  marking.  On  the 
base  of  the  marker  is  mounted  a  conical 
chuck  for  taking  the  nose  of  the  forg- 
ing, which  is  protected  from  burrs  by 
thin  copper  sheets.  On  top  of  the  up- 
rights is  a  yoke  supporting  the  air- 
hoist cylinder,  which  lifts,  the  weight 
after  the  blow  has  been  delivered.  The 
weight,  when  released  by  opening  the 
air-exhaust  valves,  drops  by  gravity.  The  letters  shown  in 
the  pocket  at  the  right  are  for  marking  the  lot  and  serial 
numbers  by  hand.   The  forging  is  taken  from  the  band- 


ing press  and  set  nose  down  in  the  chuck  shown.  The 
letter  die  in  the  dieplate  is  placed  over  the  base  of  the 
shell  and  the  weight  of  550  lb.  dropped  from  a  height 
of  2  feet. 

The  forging  is  next  weighed  and  gaged  in  accordance 
with  Fig.  15.  The  length  is  taken  by  the  gage  shown  in 
Fig.  16  and  the  depth  of  cavity  by  the  gage  shown  in  Fig. 
17.  The  diameter  is  taken  with  micrometers  and  all  the 
dimensions  are  marked  on  the  forging  as  indicated  in 
Fig.  15.  The  forging,  therefore,  goes  to  the  finishing 
lathes,  operation  8,  with  the  necessary  information  for  an 
accurate  finish.  The  man  in  charge  of  the  job  checks 
the  gaging,  operation  7,  before  the  finish-cuts  are  taken. 

Fitting  24-in.  LeBlond  lathes  for  finishing  the  forgings, 
operation  8,  was  one  of  the  most  difficult  and  costly  equip- 
ments made.  Eef erring  to  Fig.  18,  the  mandrel  block  was 
first  made  of  cast  steel ;  but  the  castings  would  either  take 
a  set  or  be  so  porous  that  they  would  spring.  The  block, 
as  fitted  at  present,  is  made  of  forged  steel.  This  block 
screws  over  the  hollow  spindle  of  the  lathe.  Through  the 
hollow  spindle  from  the  back  of  the  lathe  runs  a  forged 
steel  rod  that  screws  into  the  expanding  mandrel  A,  which 
is  made  of  forged  steel  casehardened.  The  jaws  B  are 
of  tempered  tool  steel  and  are  7  in.  long,  thus  giving  a 
grip  practically  the  entire  length  of  the  cylinder  cavity. 


— s 


FIG.  21.    FINISHING,  OPERATION  8 


FIG.  22.    WEIGHING  AND  GAGING,  OPERATION  8 

The  diameter  of  the  jaws  is  slightly  less  than  4  in., 
enough  to  enter  the  forging,  and  is  accurately  ground  to 
size.  A  handwheel  at  the  end  of  the  lathe  fits  the  mandrel 
nut.  By  turning  this  wheel  the  mandrel  A  is  drawn 
back,  the  taper  forcing  the  jaws  B  hard  out  against  the 
cavity  of  the  shell  and  giving  a  good  grip.  The  mandrel 
is  tested  daily  for  trueness;  a  few  forgings  are  tested 
daily  for  eccentricity  by  means  of  the  gage,  Fig.  19.  The 
maximum  eccentricity  obtained  was  0.015  in.;  the  aver- 
age is  about  0.005  in.  This  small  eccentricity  is  due 
to  the  spring  in  the  turret  head  when  an  exceptionally 
hard  forging  is  being  machined.  The  cutting  tool  being 
at  the  corner  of  the  turret  does  not  give  the  required 
stiffness  when  working  on  hard  forgings. 

These  lathes  were  not  large  enough  to  fit  a  positive- 
acting  radius-turning  arm  similar  to  the  one  fitted  to 
the  Hamilton  lathe  for  the  rough-turning,  so  the  profiling 
attachment  shown  in  Fig.  20  was  designed.  The  cast- 
iron  radius  form  A  is  bolted  to  the  taper  attachment  at 
the  back  of  the  lathe.  A  cast-steel  guide  bracket  is 
bolted  to  the  tool  carriage.     Other  brackets  are  bolted  to 


[67] 


the .  bedplate  at  the  back  of  the  lathe  and  support  the 
bar  B,  which  acts  as  a  trolley  for  the  rollers  of  the  guide 
bracket.  The  cast-steel  roller  bracket  C  inside  the  guide 
bracket  is  bolted  to  the  crossfeed  screw. 
A  f-in.  wire  cable  is  attached  to  the 
roller  bracket,  is  led  over  the  pulley 
D  and  made  fast  to  a  200-lb.  weight 
at  the  back  of  the  lathe.  The  base- 
plug  forgings  shown  in  the  photo- 
graph were  added  to  increase  the 
weight.  The  design  works  perfectly 
on  ordinary  forgings,  but  some  of  the 
forgings  are  so  hard  that  the  pull  is 
insufficient  to  hold  the  tool  to  a  full 
cutting  depth.  This  tendency  of  the 
tool  to  leave  the  shell  has  been  over- 
come by  using  a  second  plate  and 
roller  below  the  one  shown,  with  the 
curve  away  from  the  lathe.  When  the 
roller  tends  to  leave  the  radius  form 
the  second  form  takes  the  pressure.  A 
spring  was  tried  out,  and  it  worked 
well  when  the  tension  was  maintained, 
but  some  operators  were  careless  and 
the  form  was  substituted  for  the  spring. 
The  turret  head  fitted  to  the  tool 
carriage  of  these  lathes  is  an  ordinary 
square  turret  head  made  of  cast 
steel  and  is  secured  in  the  desired  posi- 
tions by  means  of  the  lock  screw. 
The  wide  copper  cutting  tool  and  gang 
tools  for  cutting  the  grooves  in  the  copper  band  are  se- 
cured near  the  middle  of  the  side,  while  the  steel  cut- 
ting tools  are  secured  at  the  corners.  Referring  to  Fig. 
21,  the  sequence  of  operations  and  tools  used  is  as  fol- 
lows :  Cut  groove  in  rear  of  copper  band,  tool  marked 
G;  shape  copper  band,  tool  B;  cut  grooves  in  copper 
band,  tool  C ;  remove  burrs  and  finish  copper  band  to 
size,  tool  B;  turn  bourrelet  and  radius,  tools  D  and  E; 


Counterboring  Tool, 
Qages  and  Guides 


sign  to  those  fitted  to  the  Gisholt  turret  lathes.  The 
chuck  head  screws  on  the  lathe  spindle  instead  of  bolting 
to  the  faceplate,  as  with  the  Gisholts.    The  other  features 


PIG.  23.    THREADING  THE  BASE  IN  A  LE  BLOND  LATHE,  OPERATION  9 


of  the  design  are  similar  in  all  respects  to  those  described 
for  the  Gisholt  machines.  On  account  of  the  weight  of 
this  chuck  and  the  great  overhang  (17  in.),  the  steady- 
rest  shown  in  Fig.  23,  is  used.  The  turret  head  for  hold- 
ing the  tools  is  similar  to  the  one  used  in  operation  8. 
In  this  design,  however,  all  the  tools  are  held  at  the  corn- 
ers and  the  head  is  bolted  to  the  crossfeed  for  working  in 
the  cavity  of  the  shell. 

Fig.  24  shows  how  the  shell  is  held  and  how  the  turret 
head  is  fitted  with  cutting  tools  and  stops,  also  the  se- 
quence of  operations  in  threading.  A  chasing  tool  with 
six  chasing  threads  has  been  substituted  recently  for  the 
single-point  thread-cutting  tool  B,  and  tool  C  has  been 
fitted  with  a  lip  that  cuts  the  counterbore  for  the  base 
plug,  so  that  the  counterboring  tool  on  the  tailstock  is 
more  of  a  forming  tool.  These  changes  were  made  to  in- 
crease the  production.    The  tool  A  is  shown  in  the  shell ; 


--■-. — > 


FIG. 


24.     TOOLS    USED    IN   THREADING    THE    BASE    OP 
6-IN.    PROJECTILES.    OPERATION    9 


remove  shell,  weigh  and  gage  as  per  Fig.  22,  correct 
weight  by  turning  cylinder  of  shell  between  copper 
band  and  bourrelet,  tools  A  and  F;  turn  point  of  shell, 
tool  G,  reweigh  and  mark  weight  on  shell.  Turning 
tools  D,  E,  A,  F  and  G  are  of  f  x  1^-in.  Mid  vale  tool 
steel ;  B  is  of  carbon  steel  2|xl  in. ;  the  gang  tools  0 
are  of  tungsten  special.  The  cutting  compound  pre- 
viously described  is  used  in  these  machines.  The  speed  of 
each  machine  is  80  r.p.m.  and  the  feed  1/40  inch. 

The  18-in.  by  8-ft.  LeBlond  lathes  were  fitted  with 
collet  chucks  for  cutting  the  threads  in  the  base  of  the 
forging,  operation  9.     These  chucks  are  similar  in  de- 


ft r  a~ 


— 1-6 

Inside 


PIG.  25.    TANKS  AND  NOZZLES  FOR  WASHING  3- 
6-IN.   PROJECTILES,   OPERATION   10 


AMP 


[68] 


the  head  revolves  clockwise.  The  sizing  tap  E  and  the 
master  rectifying  tap  are  inserted  in  the  tailstock.  The 
sizing  counterboring  tool  is  shown  at  F. 

The  projectile  is  next  thoroughly  washed  in  a  boiling 
solution  of  soda  and  lye  water  to  remove  all  oil  and 
grease,  operation  10.  Fig.  25  shows  the  tanks  fitted  for 
both  6-  and  3-in.  projectiles.  The  pump  shown  on  the 
column  in  Fig.  26  forces  the 
boiling    mixture    through    the 


FIG.  26.    VIEW  OF  WASHING  TANKS  AND  DRAIN  BOARD,  OPERATION  10 


spraying  nozzle  shown  for  washing  the  cavity.  This  illus- 
tration also  shows  a  forging  in  the  tongs  just  lifted  from 
the  washing  tank  by  means  of  the  air  cylinder.  This 
air  cylinder  travels  on  an  overhead  trolley.  The  shell 
is  next  suspended  in  the  second  tank,  which  contains 
clear,  boiling  water  for  rinsing. 

The  lacquering,  operation  11,  as  originally  designed  was 
to  be  done  on  a  tipple.  A  thread  guard  bushing  was 
screwed  in  the  base,  the  lacquer  poured  in  hot,  the  shell 
revolved  and  the  lacquer  poured  out.  The  guard  did  not 
prevent  the  lacquer  running  into  the  threads.  Also  the 
time  required  for  screwing  the  bushing  in  and  out  was  as 
much  as  was  required  when  using  a  brush  and  painting 
by  hand.  No  time  is  lost,  because  another  shell  is  being 
washed  while  the  lacquering  is  being  done. 

The  base  plugs  are  next  installed,  operation  12,  the 
projectile  is  dropped  into  the  swinging  chuck  shown  in 
Fig.  27  and  the  base  plug  screwed  in  by  means  of  a  special 


cone  on  each  end  is  so  centered  that  when  revolved  by 
hand,  these  cones  will  alternately  engage  the  driving 
disk.  A  spring  stop  is  provided  for  holding  the  arm  in 
place  while  the  shell  is  being  painted.  While  one  shell  is 
being  painted,  the  shell  that  has  already  been  painted 
is  removed  from  the  idle  disk  by  the  tongs,  Fig.  29,  and  a 
fresh  shell  put  on.  From  here  the  shell  goes  out  to  the 
shipping  station,  where  it  is  given  its 
final  inspection  and  stamped  before 
being  racked.  The  only  special  equip- 
ment made  for  machining  the  base 
plugs  was  a  mandrel  for  finish-turn- 
ing the  outside  of  the  plugs ;  this  man- 
drel was  fitted  to  the  engine  lathe. 
Operation  14  consists  in  rough-turning 
the  face  and  body  of  the  base  plug.  The 
forging  is  held  by  the  flange  in  a 
four-jawed  chuck  of  a  2-in.  Jones  & 
Lamson  turret  lathe.  The  inside  face 
of  the  base  plug  is  first  turned  to  about 
Iff  in.  from  the  inner  face  of  the 
flange.  Next  the  thread  space  is 
turned  the  entire  length,  leaving  the 
diameter  of  the  forgings  about  A.\  in.;  100  forgings  are 
finished  in  this  operation  and  the  machine  is  then 
changed  for  operation  15.  The  forging  is  chucked  on  the 
thread  space  and  the  flange  and  the  fuse  hole  finished. 
A  small  drill  press  is  used  for  drilling  the  holes  in  the 
base  plug  for  the  spanner  wrench,  operation  15.  The 
forging  is  bolted  to  the  table  and  two  |-in.  holes  drilled, 
stops  for  depth  being  used. 

The  base  plugs  are  threaded,  operation  16,  in  a  Le 
Blond  engine  lathe,  a  special  mandrel  being  employed. 


FIG.   27.     TRUNNION  STANDARD   CHUCK  FOR   INSTALLING 
BASE   PLUGS,    6-IN.    PROJECTILES,    OPERATION    12 

wrench  which  fits  the  two  holes.  Fig.  28  shows  the  layout 
of  these  tables  and  the  sequence  of  operations.  After  the 
plug  is  installed,  the  forging  is  weighed  on  the  scales 
shown  and  the  final  weight  is  stamped  on  the  base  by 
hand.  The  number  of  the  plug  is  also  stamped  by  hand  to 
agree  with  the  number  of  the  projectile.  This  illus- 
tration also  shows  the  painting  rig,  operation  13,  at  the 
left.  Briefly,  it  consists  of  a  constant-speed  motor  which 
runs  at  1200  r.p.m.  and  is  geared  down  to  drive  a  conical 
disk  at  88  r.p.m.     A  swinging  arm  carrying  a  cast-iron 


FIG.  2  9.      DETAILS  OF  TONGS  USED  IN  HANDLING  FRESHLY 
PAINTED    6-IN.    PROJECTILES,    OPERATION    10 

The  flange  is  turned  to  4.748  in.  in  diameter  and  faced 
to  a  thickness  of  0.35  in.  The  thread  relief  and  the 
threads  are  then  cut  7  thread,  left  hand,  IT.  S.  S.  form, 
each  plug  being  tested  with  a  ring  gage.  The  plugs  are 
fitted  in  projectiles  in  operation  8.  The  cost  of  equipping 
all  the  machines  was  less  than  $5000,  including  labor  and 
indirect  and  material  charges.  All  the  special  equip- 
ment was  installed  and  the  machines  ready  to  start  work 
when  the  first  shipment  of  forgings  was  received. 

The  manufacture  of  projectiles  at  the  Puget  Sound 
navy  yard  is  secondary  to  the  regular  routine  repair  work 
on  ships  and  only  a  few  machines  were  utilized.  The  out- 
put of  eleven  machines  is  18  projectiles  per  8-hour  day 
and  the  average  cost  for  direct  labor  $1.75  per  shell. 

In  view  of  the  large  amount  of  detailed  information 
already  published  in  these  columns  on  the  making  of  pro- 


[69] 


jectiles  of  various  sizes,  it  has  not  been  considered  neces- 
sary to  go  into  the  minute  details  of  each  and  every 
operation.  The  operations  described  and  the  equipment 
shown  will,  however,  give  sufficient  information  to  enable 
anyone  to  proceed  with  the  work  with  very  little  delay  and 
with  comparatively  slight  modifications  of  his  present 
equipment.  With  these  methods  as  a  basis  and  the  in- 
formation as  to  cost  as  a  guide  in  making  estimates,  there 
should  be  no  delay  in  getting  contracts  started,  should  a 


large  supply  of  shells  be- 
come necessary,  as  now 
seems  likely  to  be  the  case. 
By  carefully  studying  the 
needed  modifications  of 
standard  machines,  it  will 
be  found  that  these  changes 
can  probably  be  made  before 
forcing's    can    be    obtained. 


FIG.  28.     WASHING,  LACQUERING,  INSTALLING  BASE  PLUGS  AND  PAINTING 


[70] 


Copyright,  1917,  McOraw-HIll  Publishing  Co.,  Inc 


The  Ordnance  Department  requirements  for  brass  cart- 
ridge cases  of  all  types  used  by  mobile  artillery  are  given 
in  the  following  specifications : 

1.  All  cartridge  cases  will  be  constructed  in  accordance 
with  drawings  provided  or  approved  by  the  Chief  of  Ordnance, 
and  no  deviation  therefrom  will  be  allowed  without  his 
authority. 

2.  The  necessary  working  gages,  templets,  etc.,  will  be 
furnished  by  the  contractor  except  such  as  the  Ordnance 
Department  may  furnish  for  inspection  purposes  exclusively. 
The  working  gages  furnished  by  the  contractor  will  conform 
to  the  inspection  gages. 

3.  The  manufacture  of  the  articles  contracted  for  -and  of 
all  material  therefor  .shall  be  open  to  inspection  by  the 
officers  and  employees  of  the  Ordnance  Department  assigned 
to  duty  for  that  purpose  and  shall  in  all  its  details  and  in  all 
its  stages  receive  the  approval  of  the  inspector  or  such  of  his 
assistants  as  he  may  designate. 

4.  A  lot  of  cartridge  cases  of  calibers  up  to  and  including 
3.8  in.  will  consist  of  20,000  cases.  A  lot  or  cartridge  cases 
of  4.7  in.  or  greater  diameter  will  consist  of  10,000  cases. 

5.  Before  beginning  the  manufacture  of  cartridge  cases  in 
quantity,  the  contractor  will  be  required  to  demonstrate  to 
the  satisfaction  of  the  inspector,  in  the  case  of  at  least  one 
caliber,  by  the  actual  firing  test  prescribed  below  and  by 
microscopic  examination  that  he  has  established  such  methods 
of  manufacture  as  will  produce  cartridge  cases  that  will  be 
satisfactory  in  service  and  of  a  crystalline  structure  in  all 
parts  satisfactory  to  the  inspector. 

6.  This  ballistic  test  will  consist  of  firing  three  cases,  five 
rounds  each,  at  a  pressure  12  per  cent,  above  the  maximum 
powder  pressure  allowed  by  the  powder  specifications  in  the 
particular  gun  or  howitzer  for  which  the  cartridge  cases  are 
intended.  The  cases  will  be  resized  after  each  round;  and 
after  five  rounds  have  been  fired  and  the  cases  have  been 
resized  four  times,  none  of  them  shall  show  longitudinal  or 
transverse  cracks,  bulges  or  other  defects  that  will  prevent 
complete  obturation  or  in  any  other  way  affect  their  service- 
ability for  further  use. 

7.  If  during  the  firing  any  case  swells  to  such  an  extent 
that  it  cannot  be  extracted  by  the  service  extractor  of  the 
cannon,   it  shall  be   considered  unfit  for  further  use. 

In  addition  to  the  preliminary  ballistic  test  prescribed  in 
the  preceding  paragraphs,  not  less  than  five  cases  will  be 
sectionalized  and  microscopically  examined  to  determine 
whether  the  various  mechanical  operations  and  subsequent 
heat-treatments  have  been  such  as  to  leave  the  crystalline 
structure  of  the  material  in  proper  condition  for  storage. 
These  sectionalized  cases  will  also  be  examined  to  see  whether 
the  walls  or  heads  of  the  cases  show  any  folds  either  external 
or  internal 


8.  As  the  object  of  the  preliminary  test  is  to  determine 
whether  the  manufacturer  has  so  regulated  the  mechanical 
and  heat-treating  operations  as  to  produce  satisfactory  cases, 
and  as  it  is  not  a  question  of  accepting  or  rejecting  a  lot  as 
the  result  of  this  test,  any  further  preliminary  tests  that  he 
may  desire  will  be  made  at  his  expense. 

9.  An  analysis  will  not  be  required  of  the  materials  used 
in  making  the  brass,  but  the  finished  brass  will  be  analyzed 
and  must  in  all  cases  show  a  total  copper  and  zinc  content 
not  below  99.88  per  cent,  with  a  lead  content  not  above  0.12 
per  cent,  and  an  iron  content  not  above  0.02  per  cent,  with 
negative    results  as   to   tin,   antimony,    bismuth   and   cadmium. 

Any  spelter  and  copper  that  will  give  the  above  results 
may  be  used  by  the  contractor  at  his  own  risk  subject  to  the 
chemical,  ballistic  and  microscopic  tests  herein  prescribed. 

The  chemical  analysis  of  the  brass  used  in  cartridge  cases 
3.8  in.  in  diameter  and  under  will  have  a  copper  content  of  68 
per  cent,  plus  or  minus  1  per  cent,  and  a  zinc  content  of  32 
per  cent,  plus  or  minus  1  per  cent.  The  brass  used  in  cart- 
ridge cases  of  4.7-in.  diameter  and  larger  must  show  a  copper 
content  of  70  per  cent,  plus  or  minus  1  per  cent,  and  a  zinc 
content  of  30  per  cent,  plus  or  minus  1  per  cent. 

10.  Eight  cartridge  cases  will  be  selected  from  each  lot 
for  microscopic  examination  and  a  chemical  examination  and 
for  ballistic  test.  Five  of  these  cases  will  be  sectionalized, 
polished,  etched  and  examined  microscopically  to  determine 
the  crystalline  condition  of  the  material.  Chemical  samples 
for  analysis  will  also  be  selected  from  these  five  cases.  The 
remaining  three  cases  will  be  subjected  to  the  same  ballistic 
test  as  prescribed  for  the  preliminary  test  in  paragraph  t> 
above. 

11.  Should  any  or  all  of  the  cases  selected  fail  on  the 
ballistic  test,  the  contractor  is  entitled  to  a  retest  at  his  own 
expense.  In  this  event  five  cases  ■will  be  selected  by  the 
inspector,  and  the  ballistic  test  as  prescribed  above  will  be 
repeated.  If  the  retest  is  satisfactory  as  to  all  the  cases,  the 
lot  will  be  accepted;  and  if  not  satisfactory,  it  will  be  finally 
rejected  and  no  further  retest  allowed. 

12.  The  contractor  must  have  at  his  works  or  convenient 
thereto  the  necessary  apparatus  for  making  the  chemical 
analysis  prescribed  and  must  in  addition  have  a  satisfactory, 
modern,  metallurgical  microscope  and  the  necessary  equip- 
ment to  enable  microscopic  examination  of  the  metal  in  the 
cartridge  cases  to  be  made. 

13.  The  manufacturer  must  have  installed  the  necessary 
suitable  pyrometers  to  enable  the  inspector  to  check  at  any 
time  the  temperature  of  the  annealing  operations. 

14.  The  upper  portion,  of  the  case  after  the  last  drawing: 
operation  will  be  annealed  at  a  temperature  of  from  400  to 
450  cleg.  C.  In  the  annealings  between  drawings  the  tempera- 
ture will  in  no  case  exceed  650  deg.  C. 


[71] 


Stamp  Lot Number  of ' 
Ammunition  0.02"Deep'< 


■H03&- 


Buff  inside  of  Case 
before  Soldering. 
Solder  with  soft  Solder 


Stamp  Name  and  Model 
of  Gun,  Place  and  year  of 
Manufacture  0.02" Deep 


Alter  assembling,  paint 
Groove  as  follows  ■ 
Red  for  HI.  Shrapnel. 
Yellow  for  Com.  Shrapnel, 
Black  for  H.L  Shell 


-Finish f appro*.  0.2" back,  from  Shoulder 

Qi4tS'-m 

7v// with 'Red Paint to  k 

KSeat  for  I/O  6rain  Percussion  Primer 
Rough  Bore  to  0.375  "Diam.  Mandrel 
to  0.44" Diam.  Finish  Bore  Taper 
0.4698" at  large  End.  Taper 0.00 fin 
Diam.  per  Inch  of  Length 


inR'^0.00" 
10.8  _m, 


-■^  llb'Straight 


is  fitted  with  a  Tracer 


Crimp  Cartridge  Case  at  four  Places 
in  each  of  two  Grooves  in  Projectile. 
Crimps  45°  apart 


CARTRIDGE  BRRSS  ±0005 
Cartridge   Case 


Composition  of  Solders- 
Soft  Solder' 3  Parts  Lead, 
3 Parts  Tin,  I  Part  Bismuth. 
Hard  Solder ■-  50% Lead, 
50%  tin. 


*~~ 

— 

£?lCvi 

HS? 

cs<ss 

+-  1 

t-^ 

o> 

<Vi 

t_ 

-> 

0T- 

Split  and  solder 
with  soft  Solder 


Lap  Seam,solder . 
with  hard  Solder 


^0.5^-0.005 
Use  for  Ammunition  without  Tracers 


SHEET  BRASS,  O.Ol'Thick  i  0.005" 
Diaphragm        FI6.I 


VU -2.78'-— ■> 

\< -3.Z8"-— 

Use  for.Ammunition  with  Tracers 


Solder  with, 
soft  Solder 


0.5 


§  Weight  of  Cartridge.Case-231 lb. 
Weight  of  Charge -1.625  lb. 


-'-..Solder  with 
hard  Solder 


Cartridge  Case  for  3-In.  Field  Gun,  Models  of 

1902,  1904  and  1905 

operation  1.    cupping 

Transformation — Fig.  2-B.  Machine  Used — Waterbury- 
Farrel  450-ton  hydraulic  press,  Fig.  3.  Number  of  Operators 
per  Machine — Two.  Punches  and  Punch  Holders — Punch  and 
die,  Fig.  9.  Pressure  Required — 40  tons.  Lubricant — Drawing 
and  tapering  compound,  2  lb.  New  Era  No.  4  to  1  gal.  water. 
Production — 4200  in  8  hr.  Note — Brass  disk:  Maximum  diam- 
eter, 5.805  in.;  minimum,  5.800  in.;  maximum  thickness,  0.313 
in.;  minimum,  0.308  in.;  weight,  2.544  lb.;  Fig.  2-A. 
OPERATION  2.     WASH  AND  ANNEAL 

Number  of  Operators — Three.  Description  of  Operation — 
Wash  in  plain  hot  water;  heat  in  furnace  to  1300  deg.  F.  for 
1  hr.  Apparatus  and  Equipment  Used — Tank  of  hot  water, 
annealing  furnace,  truck  and  tray,  Fig.  4.  Production — 5200 
in  8  hr. 

OPERATION  3.     PICKLE  AND  WASH 
Number    of    Operators — Two.      Description    of    Operation — 
Dipped    in   a    solution    of   6    parts   water   to    1    of   vitriol,    then 
washed  in  plain  hot  water.     Apparatus  and  Equipment  Used- 
Dipping  baskets  and  tanks,  Fig.  5.     Production — 4300  per  8  hr. 


The  various  operations  on  the  different  sizes  of  cases 
are  practically  alike,  the  main  difference  being  a  few  more 
draws  on  the  gun  cases  than  on  those  for  the  howitzers. 
The  punches,  dies  and  gages  are  all  of  the  same  general 
form,  only  the  dimensions  being  suited  to  the  several 
sizes  of  cases.  For  this  reason  detailed  descriptions  of 
the  operations  on  all  the  cartridge  cases  are  unnecessary, 
since  one  set  of  detailed  operations  will  serve  as  a  general 
guide  for  all  the  others. 

A  detailed  drawing  of  a  3-in.  field-gun  cartridge  case 
for  models  of  1902,  1901  and  1905  is  given  in  Fig.  1.  It 
shows  not  only  the  case  itself,  but  also  the  position  of  the 
primer  and  diaphragm,  together  with  details  of  the  two 
types  of   diaphragms   for  use   with   and   without   night 


FIG.  2.    STEPS  IN  THE  EVOLUTION  OF  A  3-IN.  CARTRIDGE  CASE 


[72] 


tracers.     The  various  steps  in 
are  as  follows: 


the  evolution  of  this  case 


21  Punch  primer  hole 

21-A    Drill  primer  hole  and  rough  head 


1 

Cupping 

2 

Wash  and  anneal 

a 

Pickle   and   wash 

4 

First  draw 

5 

Wash  and  anneal 

6 

Pickle  and  wash 

7 

Second  draw 

8 

Wash  and  anneal 

9 

Pickle  and  wash 

10 

Third  draw 

11 

Wash  and  anneal 

12 

Pickle  and  wash 

13 

Fourth  draw 

14 

Trim 

15 

Wash  and  anneal 

16 

Pickle  and  wash 

17 

Fifth  draw 

18 

Trim 

19 

Wash  for  heading 

20 

Heading 

22 

Broach 

22-A 

Burr  out 

23 

Point  anneal 

24 

Taper 

25 

Finish  head 

26 

Stamp 

27 

Finish  trim 

28 

Inspect 

The  principal  operations  are  illustrated  in  Fig.  2.  The 
first  step  after  the  blanking  of  the  disk  is  the  cupping, 
shown  in  Fig.  3.  The  operator  dips  the  disk  into  the 
bucket  of  drawing  compound,  places  it  in  the  die  and 
trips  the  press,  forcing  the  cup  down  through  the  die 
into  a  receptacle  beneath.  The  details  of  the  punch  and 
die  for  this  cupping  operation  may  be  seen  in  Fig.  9. 


Fig.    3 — Cupping. 


FIGS.  3  TO  8.    VARIOUS  OPERATIONS  ON  FIELD-GUN  CARTRIDGE  CASES 

Fig.    4 — Annealing.      Fig.    5 — Pickling    and  washing.     Fig.  6 — Drawing.     Fig.  7- 
Fig.  8 — Second  trimming 


-First  trimming. 


[73] 


9M"(9j)—--^\ 
US.Std.  Fitto  taper    05  Drill 
Thready  Gouge*,        l"deejz 


5 per  In.  t* 


W/5    ,    |.    -ST—.     ^ 

tupping  Punch     Finish Jg±0.005"(Harden) 


Guide  Ring 

7T00Z.  STEEL 


Finish} ±0.005" 


Cupping  Die      Al£25i? 
7Dat57ra  F/nlshfgtO.0O5' 
Harden 


X=  Stamp  Name  of  Cartridge 
Case,  Name  ofOperafion, 
Diameter  of  Die,  Place  of 
Manufacture  and  Dote 

FIG.9 
OPERATION  1 


§£  \5perln.U.S.Std.  Ib 

^Thread     Fit  to  taper      ..0.5"DrW,  I'deep 
.GaugeX^ 


0.5" Rad.' 


■  1.625' ^3.312  (3?6)-A~  2.75?-  A~.-E.75"--  -A 

^--4.937'HJt")  —  -^- 5.5"-- A 

First  Draw  Punch       _.      ,  .   .n„„r„, 
TOOL  STEEL  F/nishjgt 0.005  (Harden) 


3^ 


ins 


Fit  to  taper  Gauged 


■//.^//£^'Mi'*&. 


5perln.-y     *■ 
US.Std.  p 


Thread. 


A/.62. 


>0.25"  «- 


f*i 


V^ 


c,-A-^-055"\ 

t— J3eferJ>4<-  ■  2.5" -A~— 3.75--- ■ 


7. 


r0.45"Rad. 


-0.375" 


■4.937"(4p- '  *1» -<525 ''-  - 

Second  Draw  Punch 


7<?oi  57ra 


Finish  fg±0.005"(tiarden) 


OPERATION  7     Second  Draw  D<e 
vrtrvMiun  /  TOOL  STEEL 

Finish Jg±0.005"(Harden) 


*kl25k\<r- 

■>i  ■  W.-0.5 


0.5"Dri//,t"deep     „.„,,., 
m'totaoer'--'       ■l5A37(l5' 


05621%) 


SperlnUiStd.  >    ^m.  \ 
Thread    -^.625"^33lf(3j6) 


■6 

■4.937"(4'fb")--A« -&5 

TOOL  STEEL  Third  Draw  Punch 


'r>--A« 


Tztzjrmm 


A  OA'Rad. 
Finishfg±Q005"(Hardtn) 


Third  Draw  Die 
TOOL  STEEL 


FIG.I2 
OPERATION  10 


Finish fg±0.005"(Harden) 


OPERATION  4.  FIRST  DRAW 
Transformation — Fig.  2-C.  Machine  Used — Waterbury- 
Farrel  rack  press.  Number  of  Operators  per  Machine — Two. 
Punches  and  Punch  Holders — Punch  and  die,  Fig.  10.  Pressure 
Required — 22  tons.  Lubricant — New  Era  No.  4,  2  lb.  to  1  gal. 
water.     Production — 4300   per   8    hr. 

OPERATION   5.      WASH   AND  ANNEAL 
Number    of  Operators — Three.      Description   of   Operation — 
Same  as  before.     Production — 5600  per  8  hr. 

OPERATION  6.     PICKLE  AND  WASH 
Number    of    Operators — Two.      Description    of    Operation — 
Same  as  before.     Production — 3500  per  8  hr. 


OPERATION  7.     SECOND  DRAW 
Transformation — Fig.      2-D.       Number     of     Operators     per 


-Two.      Punches  and   Punch  Holders — Punch  and   die, 
Pressure    Required — 9    tons.      Production — 3700    per 


Machine- 
Fig.    11. 
8  hr. 

OPERATION  8.     WASH  AND  ANNEAL 
Number   of  Operators — Three.      Production — 6000   per    8    hr. 

OPERATION  9.     PICKLE  AND  WASH 
Number  of  Operators — Two.     Production — 3300  per  8  hr. 

OPERATION  10.     THIRD  DRAW 
Transformation — Fig.      2-E.        Machine     Used — Waterbury- 
Farrel  rack  press.     Number  of  Operators  per  Machine — Two. 


.Sri 


.hit  to  Taper  6a ge    „ 
$SThredd5  per  Inch  -/8-^7(^ls) 


*n 


■AM'Drill 
^  I'Deep 


t. 


■0.25 

\<ij6z$*-33etejj)  ^'---"-d"  — >k --- 

U-^S37fyg|*— *<- 14"'- 

tool  steel,  (Harden)  Finish/g  ±  0.005 
Fourth  Draw  Punch 


,FittoTaper6aqe      ,    «' 
Wsf^U-perlncr-2^1^ 


RAi  |mi| 


025*  I 

YH6t&<  -32J2'(o$- 

k-4937"0ff—A---- 18''--- 

TOOL  STEEL,  (Harden)  Finish fg  ±0.005 
Fifth  Draw  Punch 
X= Stamp  Name  of 
Cartridge  Case, 
Name  of  Operation, 
Diameter  of  Die, 
Place  ofManu 
facture  and 
Date. 


Y-0.5" 


1.125^-A 
TOOL  STEEL,(HardenjFinishJg±0.005" 

Fourth  Draw  Die, 

FIG.  13 

OPERATION  13 


high  speed  STEEiJlHarden) 
FinishJ±0.O/" 

ne.  14 

OPERATION  14 


[74] 


I.IZ5Y 


+005"^    j 


Y-0.5 


TOOL  STEEL,  (Harden)  Finish jg±0.0Q5" 
Fifth  Draw  Die 

FIG.  15 
OPERATION  17 


Punches  and  Punch  Holders — Punch  and  die,  Fig.  12.     Pressure 
Required — 7  tons.     Production — 3400  per  8  hr. 

OPERATION  11.     WASH  AND  ANNEAL 
Description  of  Operation — Heat  to  1300  deg.  F.  for  50  min. 
Production — 3400  per  8  hr. 

OPERATION    12.      PICKLE   AND   WASH 
Production — 2400  per  8  hr. 

OPERATION   13.     FOURTH  DRAW 
Transformation — Fig.     2-F.       Machine     Used — Rack     press, 
Fig.  6.     Number  of  Operators  per  Machine — Two.     Punches  and 
Punch  Holders — Punch  and  die,  Fig.  13.     Pressure  Required — 
7  tons.     Production — 2400  per  8  hr. 

OPERATION  14.     TRIM 
Machine  Used — Pratt  &  Whitney,  Fig.  7.     Number  of  Oper- 
ators per  Machine — One.     Cutting  Tools — Cutoff  tool,    Fig.   14. 
Production — 1200  per  8  hr.     Note — Trim  off  20  per  cent. 

OPERATION    15.      WASH    AND    ANNEAL 
Number   of  Operators — Three.      Description    of   Operation — 
Heat  to  1300  deg.  F.  for  50  min.     Production — 3600  per  8  Hr. 


OPERATION  16.     PICKLE  AND  WASH 
Production — 1700  per  8  hr. 

OPERATION  17.     FIFTH  DRAW 
Transformation — Fig.    2-G.      Machine    Used — Hydraulic    or 
rack  press.     Number  of  Operators  per  Machine — Two.    Punches 
and   Punch   Holders — Punch   and    die,    Fig.    15.     Pressure    Re- 
quired— 3  tons.     Production — 1900  per  8  hr. 

OPERATION  18.  TRIM 
Transformation — Fig.  2-H.  Machine  Used — Lathe,  Fig.  8. 
Number  of  Operators  per  Machine — One.  Work-Holding 
Devices — Three-jaw  universal  lathe  chuck.  Cutting  Tools — 
Cutoff  tool,  Fig.  14.  Cut  Data — 420  r.p.m.  Production — 1350 
per  8  hr. 

OPERATION   19.     WASH  FOR  HEADING 
Description   of  Operation — Wash   in   solution   of   25   lb.    6-B 
washing  compound  to  75  gal.  water.    Production — 3500  per  8  hr. 

OPERATION  20.     HEADING 
Transformation — Fig.  2-1,  minus  primer  hole.    Machine  Used 
— 1000-ton  hydraulic  press,  Fig.  16.     Number  of  Operators  per 


FIGS.   16  TO  21.    VARIOUS  PRESS  AND  MACHINING  OPERATIONS 

Fig.  16,    -Heading  the  small-size  cases.     Fig.  17 — Heading  large  cases.     Fig.   18 — Punching  primer  hole.     Fig.   19— Drilling 
and   roughing   head.     Fig.   20 — Sizing  primer  hole.     Fig.   21 — Burring  primer  hole 


[75] 


Machine — One.  Punches  and  Punch  Holders — Punch,  Fig.  22. 
Dies  and  Die  Holders — Die,  Pig.  23.  Pressure  Required — 600 
tons.  Gages — Snap  gage,  diameter  of  head,  Fig.  45,  operation 
25;  thickness  of  head,  micrometer  gage,  Fig.  24.  Production — 
800  per  8  hr. 

OPERATION  21.     PUNCH  PRIMER  HOLE 

Transformation — Fig.  2-1.  Machine  Used — Small  press,  Fig. 
18.  Number  of  Operators  per  Machine — One.  Punch  and  Die — 
Fig.  25.     Production — 2800  per  8  hr. 

OPERATION  21-A.     DRILL  PRIMER  HOLE  AND 
ROUGH  HEAD 

Machine    Used — Potter    &    Johnston    turret    lathe,    Fig.    19. 
Cutting    Tools — Tool    for    turning    under    heacl,    Fig.    26;    drill, 
reamer.       Cut    Data — 270    r.p.m.       Production — 800    per    8    hr. 
Note — This  is  only  done  when  punch  press  is  not  available. 
OPERATION  22.     BROACH 

Machine  Used — Fig.  20.     Number  of  Operators  per  Machine 
• — One.      Tool   Used — Sizing   drift   or   broach,    Fig.    27.      Special 
Fixtures — Fig.  28.     Production — 2800  per  8  hr. 
OPERATION   22-A.      BURR  OUT 

Machine  Used — Fig.  21.  Number  of  Operators  per  Machine 
—One.  Cutting  Tools — Burring  tool,  Fig.  29.  Cut  Data — Tool 
runs  750  r.p.m.     Special  Fixtures — Fig.  30. 

OPERATION  23.     POINT  ANNEAL 

Number  of  Operators — One.  Description  of  Operation — A 
case  is  placed  as  shown  in  the  machine,  Fig.  31,  the  gas  jets 
being  so  regulated  as  to  heat  the  case  a  low  red  on  the  open 
end  with  the  heat  gradually  lessening  toward  the  head;  the 
holding  spindle  revolves  about  £0  r.p.m.,  and  a  case  will  heat 
in  about  1  min.    Production — 1200  per  8  hr. 

The  cups  are  next  washed  in  plain  hot  water  to  remove 
the  soapy  drawing  solution  and  are  then  annealed.  This 
is  done  by  placing  the  cups  in  trays,  as  shown  in  Fig.  4, 
and  pushing  the  loaded  trays  into  a  furnace.  Here  they 
are  heated  to  about  1300  deg.  F.  for  an  hour;  then  the 
tray  is  pulled  out  onto  the  truck  and  run  out  into  the 
open  air.  The  tray  shown  is  filled  with  fourth-draw  cases, 
but  the  method  of  procedure  is  the  same  in  the  other 
annealing  operations. 

After  annealing,  the  cups  are  pickled  to  remove  the 
scale  and  are  then  washed  in  hot  water.     The  pickling 


the  left.  After  washing,  the  work  is  ready  for  the  first 
draw,  the  punches  and  dies  for  which  are  illustrated  in 
Fig.  10. 

The  washing,  annealing,  pickling  and  washing  follow 
each  drawing  operation  with  but  slight  variations  and 


Wr:-o.i"r. 

!  i    I  ' 

>Q.M4"M--— 1.5"-  — A 

U £A?---~J 

tool  STEEL,(Harden)FinishJg±0005 


0.5  ^ 
TOOLSTEujHarden) Finish fg  1 0.005" 


Punch 


r- 


-2.95"- 


FIG.25 
OPERATION  21      ,„  Die 

nv-3 


-LIS 


QIS"» 


;yj 


A  t 


*  i  § 


HIGH-SPEED  STEEL,  Finish  J  ±0.005 
FIG.  26 
OPERATION  2IA 


■v^L 


r — --' 

*-2.l25— 

t 
52 


//» — 

-2"~->\<--2-'--»n--2 

\3rdSectkA2"c,Sect«» 


>1  0.75' 

\2.7&y->i 


n\        0.3*^  ^'7^,0.15''  (Fini5^Z^05  " 


need  not  be  further  described.  Details  of  the  punches 
and  dies  for  the  second  draw  are  given  in  Fig.  11.  Figs. 
12  and  13  show  those  for  the  third  and  fourth  draw.  The 
latter  is  also  illustrated  in  Fig.  6.     Here  a  tank  for  the 

Head  Pin 

TOOLSTEEl/Harden) 


UPOJ ___y -j?ft7i;"±n  dp- -J 


-ii±o.or 

-I2.875"±0.02---- 
Bolf--'''TOOL  STEEL.  (Harden).  Finishfg ±0.005" 
COLD  DRAWNSTEEL 


Punch 


0.03fa 


Stamp  Name  of 
Cartridge  Case 
Operation,  Placeof_ 
Manufacture  and 


RnishftQOI 


FIG.  22 


Y"2.5\  ^-075" 


KSK^gg*"*    rOOL5TEEL(Harden)nn,shfg*0.005' 


Ring 


FIG.  23 


ZS^Sg^^""^^' 


*• 


O.I2i"TapStd: 


■3JS7M 


^f-fc£3:;; :.; ..;.-.,. ;,jfon  ., 

WlOIFlfStd 


0.562ffl* 

TOOL  STEEL  (Harden) 
nmshfffid.005" 
Scale 


-05  Drill 
MACHINE STEEL.  Finish/±O.Ol"       COLD  DRAWN  STEEL.  Fnishf±QOl" 
m   .        Rod  Base     &  fbrQO&tsunk  Rod 

'} +0000  "0002"-. 


^S5    .    G^jft 


<5>  a 


0.375' ,Tap5fd. 
075"-0000' 
-0.003 


2.2" -0.000". 
i--  +0002 


Assembly 


„---     A    _ 

<! L 

—17- 

:> 

■k  a 

i   ^! 

[A  ; 

_         T"" 

-*--   _ 

\*-4.75"-A- 
0.625" 

s 


■-  .0.75 


y.075" 

CAST  IRON.tQOr 
Base  Plate 


SS 


Q}S\  ^--245"- 
O^Deeo  MACHINE STEEL.Finishfc0.0l 'Divide -into 50    ForOOWtsunk 
r  Guide-Left        Equal  Parts      HeadStdScrew 

,p.l25"5td.Thd  machine ■STEEL. Finish/ tQOl"  n7ri.nnnn"nnn?"  MThrU 

r^i     ^jq_^  Guide-Right  ,   075+0.000-0.002 .Otdjhrd 

®  *to4  *       ©GTS™ 

W*     ^Jm  0375^21%^ 


TOOLSTEEL(Harden)Rnish/±00l 
Point 

~^- 1.125+000^0002"  DnVe, 

_i    \fi/A-    22.5" -A/.e^. 

-262--  ->i 

COLD  DRAWNSTEEL. 
Fnish/±0.0l" 

MACHINE  STEEL.  Finish/ ±0.01 "  P°S+ 

Post  Base 

FIG.  24 
OPERATION  20 


0875" 


MACHINE  STEEL.  Finish/ ±001 
Post  Head 


v-2.25-->*-2.25"A     S 

U  —45II J 

MACHINE  STEEL,  Finish /±0.0l" 
Clamp  Screw 


,QII5tdThd. 


MACHINE  STEEL,  Finish/±0.0l' 
Screw 


is  done  as  shown  in  Fig.  5.  The  parts  to  be  pickled  are 
placed  in  a  large  basket,  as  shown  at  the  right,  and  im- 
mersed in  the  solution.  When  the  scale  has  all  been  cut, 
the  basket  is  raised  and  run  along  to  the  hot-water  tank  at 


drawing  solution  is  shown  just  at  the  left  of  the  press. 
The  operator  dips  his  work  into  this  tank  before  he  places 
it  in  the  die.  After  the  fourth  draw  the  case  is  trimmed 
as  shown  in  Fig.  7,  about  20  per  cent,  of  it  being  removed. 


[76] 


The  fifth-draw  punches  and  dies  are  illustrated  in 
F/ig.  15,  and  the  trimming  operation,  which  immediately 
follows,  is  shown  in  Fig.  8.  After  the  case  is  trimmed, 
it  is  washed  in  a  special  solution;  then  it  is  headed  in  a 
hydraulic  press,  as  shown  in  Fig.  16.  Two  dies  are  used 
in  this  press,  so  that  the  work  is  practically  continuous. 
A  case  is  placed  in  one  die,  as  at  A,  while  the  heading 
punch  B  is  descending  on  the  one  at  C.  The  die  at  C 
is  then  pulled  back  and  the  one  at  A  pushed  into  its 
place,  and  so  on.    Details  of  the  die  are  given  in  Fig.  23. 

A  press,  Fig.  17,  is  fitted  differently  for  heading  and  is 
used  principally  on  the  larger  sizes.     The  case  is  held  in 


punching  operation,  and  the  drift  is  shown  in  Fig.  27. 
Burring  of  the  primer  hole  is  done  from  the  inside  on 
a  small  lathe  fitted  as  shown  in  Fig.  21.  The  burring 
tool,  detailed  in  Fig.  29,  is  carried  on  the  end  of  a  long 
rod  chucked  as  shown.  The  case  is  placed  on  an  adjusta- 
ble carrier  that  slides  along  the  lathe  bed.  The  adjust- 
ment of  the  V's  allows  the  fixture  to  be  used  for  all  sizes 
of  cases.    Details  are  given  in  Fig.  30. 

Point  annealing  of  the  cases  is  done  in  special  ma- 
chines, Figs.  31  and  32.  The  case  to  be  annealed  is  placed 
on  the  revolving  table,  and  the  gas  jets  play  on  it  in  such 
a  way  as  to  heat  the  mouth  end  to  a  good  red  heat.    This 


TOOL  STEEL 

F/nish/±Q005"(Harden) 


•:. 


0365r 


1>> 


V  -*\0455 

S  laoof 


&  - 


$ -4 


0.43" 


0.4' 


■>\0.43"Y- 


Is 

•£"•3 


*•  2 


•5  1 


Note-. 


A^U 


T 
6perln. 
USStd.Threod^. 

U -3.375^-3^- 
U 


Material  Cold-drawn  Steel,  Finish f±  O.OI",  except  where  marked 

0.067?. 


18. 


*\  •  \<-0.%" 


Plug  for  2.95" Mtn.Gun  Case 


*i  •  V'0.95' 
Plug  for 3"Mtn.Howitzer Case 


Plug  for  4.7"6un  &  How.  Cases 
03" 


U-~ 7*- *l 

025*l"5td.FilisterheadSteelScrews 

0.25"Std.  Brass  Washer 
0375"'*'**'  037yDrive-**-'ri± 

Drive    ' ;  -      ;  '-t& 


FIG.27 


1  l"U-3£p-'- 
W-4.25"-^ 


~T^«nPlug  for  3"Field  Gun  Case 
l«  •  L/27A*  *!*"      TT 


\-„4gf!-4  FIG.28 

Plug  for 3.8'How. Case 


325».Ta25ia005 

Plug  for  6*How.Case 


U-0375 

I  M-az" 


\----8J5 
Finish/ 


•+aooo"..*\  ^ 
-0.005"     ^  $§§ 

Shaft  ' 


0675". 


0494" 


^ 


-fr- 


Cv;^:....5^V^^H 


6  Teeth 


-3.75- 


.  TOOL  STEEL 

^  Finish f±aOl"( Harden) 
End  Mill        (aZ5^0375"Std.Steel  Setscnw) 

I- 


^^-0.6^05^     ■% 

[<..-//». -4  TOOL  STEEL 

Finishf±0.0l'(Harden) 

Pilot 


\ 


j  OI87'(&")Ra>m 


E4" 


U- 7.375 

Holder    (O.I67?j$")xG875"5teel Pin-Drive 
FIG.  29 


Assembled  Views 


U--A -1 

0375"Std.  Wrought  Iron  Pipe 
A-6.45"andO.B5" 

Distance  Piece 

V?     r-  MS?    m"  0.& 

t375"^r-;:5--i%  Tfo % 

'.l^M^j'K  '0375^ '°\    Q' 
0.&5"*' 

■925" A 

,  MACHINE  STEEL 

Q75*0.65"5td.Fi/isterhead  Steel  Screws 

Tie  Plate 

"W.TOOL  STEEL 


*9- 


J225%pStd. 

W~\^A5"    . 


3 


Qfi\ 


For  0.?5"FilisterheadStd.Screw 

i       'I- — iv 


0.375"-A-V- 


taoo5 

Guide  Plate 


nv^     7£n4T     J°w  Support 
0375-  *^Q49  attyrstdfilisterhead 

MACHINE  STEEL  SteelScrews 


Visas' 

Finish f±QDl"( Harden) 
Roller 


FIG.  30 


NOTE:  FIG.27,28  OPERATION  22.      FIG.29,30  OPERATION  22a. 


the  die  at  A.  The  die  is  held  in  a  carrier  B,  which  slides 
on  the  rails  C  and  is  run  in  or  out  by  means  of  a  small 
hydraulic  cylinder  and  piston  at  the  back. 

Primer  holes  are  punched  in  the  small  press,  Fig.  18. 
The  die  is  carried  in  a  post  hinged  at  the  bottom  so  that 
the  work  and  the  die  may  be  swung  in  or  out  under  the 
punch.    Details  of  the  punch  and  die  are  given  in  Fig.  25. 

Ordinarily,  all  primer  holes  in  this  type  of  case  are 
punched;  but  where  no  press  is  available,  the  hole  is 
drilled  and  the  head  roughed  off  in  a  turret  lathe,  as 
shown  in  Fig.  19.  An  ordinary  twist  drill  and  a  turn- 
ing tool,  Fig.  26,  are  used.  Following  either  the  punch- 
ing or  drilling  of  the  primer  hole,  a  broach  or  drift  is 
forced  through  as  shown  in  Fig.  20,  to  size  the  hole  ac- 
curately.    The  fixture  used  is  made  like  that  for  the 


heating  gradually  lessens  toward  the  head  of  the  case,  so 
that  the  case  is  left  hard  on  the  head  end,  but  increasingly 
soft  toward  the  mouth,  so  that  as  the  case  is  forced  into 
the  tapering  die,  as  shown  in  Fig.  33,  the  head  end  does 
not  buckle  under  the  pressure  and  the  case  is  tapered 
toward  the  open  end.  The  tapering  die  is  illustrated  in 
Fig.  37.  The  heads  are  finished  in  a  semi-automatic, 
Fig.  34.  In  this  machine  the  head  is  faced,  chamfered, 
the  paint  groove  cut  and  the  primer  hole  reamed  and 
counterbored.  The  tools  used  are  given  in  detail  in  Figs. 
38,  39,  40,  41,  42  and  43.  The  gages  are  given  in  Figs. 
24,  44  and  45. 

Following  the  finishing  of  the  head,  it  is  stamped  in  a 
hydraulic  press,  Fig.  35,  details  of  the  fixture  being  given 
in  Fig.  46.    The  final  trimming  to  exact  length  is  done 


[77] 


in  a  specially  fitted  turret  lathe,  Fig.  36.  The  head  is 
held  in  a  turret  chuck  A  and  pressed  to  the  revolving 
tool  B  on  the  spindle.  This  chuck  and  tool  are  shown 
in  detail  in  Figs.  47  and  48  respectively.  Inspection  fol- 
lows, some  of  the  gages  for  this  purpose  being  shown  in 
Figs.  50,  51  and  52. 

OPERATION  24.     TAPERING 

Machine  Used — Punch  press,  Fig.  33.  Number  of  Operators 
per  Machine — One.  Dies  and  Die  Holders — Die,  Fig.  37.  Pres- 
sure Required — 12  tons.     Production — 1800  per  8  hr. 

OPERATION  25.     FINISH  HEAD 

Transformation — Fig.  25.  Machine  Used — Potter  &  John- 
ston automatic,  Fig.  34.  Number  of  Machines  per  Operator — 
Two.  Cutting  Tools — Circular  form  tool,  Fig.  38;  facing  tool, 
Fig.  39;  chamfering  tool,  Fig.  40;  grooving  tool,  Fig.  41; 
reamer,    Fig.    42;    counterbore,    Fig.    43.      Cut   Data — 250    r.p.m. 


Gages — Primer-hole  gage,  Fig.  44;  diameter  under  head,  Fig. 
45;  primer-hole  counterbore,  Fig.  44;  thickness  of  head,  Figs. 
24  and  44;  diameter  of  head,  Fig.  45.     Production — 500  per  8  hr. 

OPERATION   26.      STAMP 
Transformation — Fig.   2-K.     Machine  Used — 30-ton  hydrau- 
lic   press,    Fig.    35.      Number   of    Operators    per    Machine — One. 
Stamp — See  Fig.  1.     Pressure  Required — 13  tons.     Special  Fix- 
tures— Fig.  46.     Production — 2500  per  8  hr. 

OPERATION  27.  FINISH  TRIM 
Machine  Used — Turret  lathe,  Fig.  36.  Number  of  Operators 
per  Machine — One.  Work-Holding  Devices — Special  chuck. 
Fig.  47.  Tool-Holding  Devices — Fixture  (tool  holder),  Fig.  48. 
Cutting  Tools — Inside  chamfering,  Fig.  48;  outside  chamfer- 
ing, Fig.  48;  facing,  Fig.  48.  Cut  Data — 950  r.p.m.  Gages — 
Length,  Fig.  49.     Production — 1800  per  8  hr. 

OPERATION  28.  INSPECTION 
Apparatus  and  Equipment  Used — Fig.  50.  Gages — Mouth 
plug  gage,  Fig.  51;  primer-hole  gage,  Fig.  44;  primer-hole 
counterbore,  Fig.  44;  thickness  of  head,  Fig.  44;  diameter  of 
head,  Fig.  45;  diameter  under  head,  Fig.  45;  length  gage,  Fig. 
52;  cylinder  gage,  Fig.  50. 


FIGS.   31  TO  36.    ANNEALING,   PRESSING  AND  MACHINING  WORK 

Fig.  31 — Point-annealing  machine  open.     Fig.  32 — Same  machine  closed.     Fig.   33 — Tapering  the   case. 

the  head.     Fig.  35 — Stamping  the  head.     Fig.  36 — Finish   trimming 

[78] 


Fig.   34 — Machining 


Stamp:  name  of  cartridge 
case,  operation  and  die, 
place  of  manufacture  and 
date 


TOP  SECTION-^  "••MIDDLE    SECTION 

Thperinq      Die 

?TOOL   STEEL  nO.37.OR24 

finish /<at0.005"harden 


Stam^name  of  case 

d/men&on'Alp/ace  of 

manufacture  and 

dateiyear) 


A  *  1.980 fbrZ95Mt.GjnCartCase 
A  =2007^r3TieldQ/nMxt.i902pt 
,  1905  Cart  Case 


—  1 


HIGH  SPEED   STEEL 
finish ftO.O/" Harden 

A'm7"for3"Mt.tfmMod./m'//347tiotY.       FIG.  38 

A-Z007ror3.8"h'OMMod./908.CartCase  „       ., 

A=2.002"for47"Gun Mod.  1906 Cart  Case  A-/.997%r6'fio>Y.Mod  1906.  08 Cart.  Case 


P 


2'- 


@^ 


I 


T 


*i 


J.lnt0.002' 
J° 


HIGH  SPEED. .STEEL 
ffn/shjf±0.0/ttorden 

FIG.  39 

"•^i  f*omfei"  1 1  B  .JaperaOM'ttam. 

f|  j  fun ' fa)     ^  y   I V  per/n.of/enffth         $\ 


TOOL  STEEL 
finishj^taofrlarden 

FIG  40 


02&      K- 

0/87t£y\>[\^D/am  ^ 


y$    c 


U 


4<zk-//2*'---£ 


A. 


j^Gr/nd  ^i§ 


J 

a,\  i    ^  *$: J!  £/-//*/  r^ 


fin/sh/tOOi," Harden 
FIG.4I 


-P-SJU-       -jW"^ 


to 


CutbymBSS. 


Section 
A -A 


U...;...^must.^-'  >( 

7,,,/r,.j«i  I         Reamers  •* -38/2(3%)--''- >< 

-•3*S?  r%>  -- >l     Section  B-B 

Counterbore 

(finish,  Harden) 
OPERATION    25 


Rea  m  e  r 

TOOL  STEEL 

(f/n/sh,  Harden) 

FIG.  42 


-tag 

10 

Counterbore    Stop 

_       finish 
Q25x0.25"i/eadlessStd.SetScrenr 

FIG  43 


O 


l^^/^t/Wj 


it*— /-2» ---*i 

K"«  hi 


.25ii.fl5^-H2 


MACHINE  STEEL       |^ 
I-— --/4--  —  -m :-«- 1   §!§  FinishJtaOl" 
^--8.9"-^^-, 


FinishftO.Ol"    /9" 


-  Tj_» 

6perkUS.5td.Thredd  iftOOOg"  J  ,Ua  i^^ffi  JT*"^ 
8  „    .  ,  '^ -0.003    ^.H?   0.562(f6)^-^    Plunger 

Bottom  Pbst  (MACHINE STEEL)  255" 

4.7"Howitzer&6"Howitzer  _  u,ruluP<rrra 

V2J4JsSHs 


MACHINE  STEEL 


kMl  ^^^--TapforO.25^0.75" 


&\  Filisterhead 
$     \\5teel 'Screws 


'--■120 
°t0.005    Punch  Holder 


MACHINE  STEEL        0.15  Jnmi' 

FinishftO.Ol" 
^?os\(3"Mtn.HoW.)  om»  pj^OOO; 

^i3 -0.002" /  .■n5'Wad    - 
Fin'ishf±aoi"^~<^  r!-%Si'  1 


^"  f  0/^5^TapfbrQ25*/.O 

"f\i  '  I  'ftN\ Filisterhead ', 

^  JLpieel  Screws* 

(^Fin/shftaOl" 


'-  /a?°-  Punch  Holder  Bracket"^'  MACHINESTEEL 

FMsh/tOOl" ,jU^I     2S£0.00f  yftfjjjf.        aS^y 


V§! 


075"Rdd    <*2'H--.    ""§ 


0.15 


r= 


?,f  IS 

-,;,•<  *  l*6!CW  «5'1"*-*l  ''..    ,g 


-0.00" 


Assembled  Views 

.WSJ 


Top  Pos+      _ 


Post  Base 

^         /     ,,crjT,         j       IC'+O.OOO" 

6perln.U.5Std.Thread^  '■? -0.003 

3U 


FinishJtaOl" 


Post  (3"FieldGun) 


*¥?'■ 


1.5" 
MACHINESTEEL 


©: 


c^_   MACHINESTEEL 


rw/ym 


^05%  .    „ 


Finish f ±0.01" \ .7."-..  ^ 

Filling  Piece  (4.7"Gun) 


"  +0.01"  _ 

V+0.01"  FinishjiO.01"  Qb+0.0i 

Top  Post^.7^6%^;    FinishftaOl" (MACHINE STEEL) 

Oi.56"  D-0375%r47"howitzer        ToP  pos+  f<7"W 
Z~6J6" U-0.25" „  6"    „ 


^2.1^-- -8.75" 

S* ,- -12.85"- 

Finish/tO.OI  Bottom  Post 

%\^.^.Q95'       „     1    (3S"Hm,2.95"Htn.Gun,4.7"6un,3Mtn.How) 

$3/%£Pa  -f>^  *=i"*=2.75"for3" Field  Guns  \  Note  for 

W^\^  ?)i^  ^3ltt"'Q-2.875"for3"Mtn.Hm.MnHow16"How\pe™ 

h=5.5"&=3.25"for4.7"How.  \  uTf 

*■-&"■    -^mach/nesteel  A=2.5"B=Z25"for47"Gtm&2.95"Mtn.Gun    ) Holder 

0-15,0.01"  ao5%    F/n/W±QOr 

Top  Post  (2.95"MountamGun) 

FIG.46  OPERATION  26 


I  Max>f?  f±  ^XM/' 


'0.b52"DnW 


^ 


Si  ^r 


,^ 


Hr* 


Lf5t 


...:-„ -v.^.J  X /^.rF     '        ™ . isW5m         u&%. j^.r-Jm"      ****&'    F®1* 

.^.^TTi-fi  Jt.JTi,  ^rj,it!I^K  rOf/t/OGRA/NP/t/ME/f  ^EOfi  20G.RA1N PltkrR        ^,' ' 

':'j'"'[1       .   r    ""'J'       '  Primer  Hole  Counterbore                 Primer  Hole  Gage  Primer  Hole  Counterbore        Primer  Hole  Gcyje 

Head   Gage                                  G                                            FORGED  STEEL  N?  5  Gage  FORGED  .STEEL  N! 

FORGED  STEEL  ALfJ                          FORGED  STEEL  A/ox                                        finish. H&G.  FORGED  STEEL  N° 3 

(tiarden&GrinJ)                       ^fmJMg                                   FIG.44.0P.25  fin,st>.  H.&G. 


finish tt.&G. 


[79] 


p 


■ ,  N 


^ 


'  ~^*aos"     L. 


8 per  In.  U.S.Std.  Thread 
-A.-M    Finish f +0.01° 


^amf) 


machine  steel  Holder 


Finish  ft  0.01" 


Assembled  View 
FIG.47 


Tr^»" 


0.656"(&)DriH0.75"deep 


4.5- *>       ^ "" ** 'MACHINE STEEL  '0.01 

101  ?^'^  Drill  ForO/5'Boft 


YRad.         -Jt.L-Q25"   COLD  DRAWN  STEEL 
.■ZgMOj-A     '     Finish f±aOl"(Case  Harden) 
k=2.95"for3"FieldCuna3"Mtn.Ho*. 
b=2£9"for2.%"Mtn.  Gun 


-4-1-05, 

6>»7/7.  US'StdJhreaa^T.43"^ 

MACHINE  STEEL  (Finish  J 10.0/") 


V-^05+0.00',, 

a,5± r-o-o'" 

TapStd. 


Chock 


te339"for3"Mtn.Howitzer 
A=3.4"forZ95"Mtn.6un 
r\=3.45"for3"Field  Gun 


\* 2.25"+0.0i"—- 


t 


> 


+0.000 


I   \       HIGH  SPEED  STEEL 

.=-1/7^    Finish fg  (Harden) 


Facing  Tool 


a'ps'-o.ooo'' 

u"  +0.002" 


HIGH  SPEED  STEEL  .'  */.  I      ^5" 

Finish fg( Harden)       *Sfi20\     +0.01" 

Ou+side  ChamferingTool 


FIG.  48 


qo6»-0.0Oi 

a*: 

J/iPik  •       k"^    Finish  fg  (Harden) f 
+0000"       |VX  I 

-&?<2?"       I  y-^> 1 

-J-fO  \     HIGH  SPEED  STEEL 

Inside  Chamfering  Tool 


FinishfiOO!'- 

./200-'' 

MACHINE  STEEL   —ilQ$~'- 

0312  (%)x/"5fd.  Hexagonal  Head  Steel  Screws 
Collar 


QOrfprill  NO.40W.&S.W.6. 
h*  •/' Maximum -H 


dS 


a098"Drill  No.40  T.D.&S.W.G. 
_u  -/ Max. "J .__ 


0.05"R'.\  U Minimum— ^\ 

U A ^°JZ5 

FORGED  STEEL  (Harden  and  Grind) 

Length  .Gage 


(3/7?. 


%j 


■-Min.  -■ 

—  C 

fORGED  STEEL  ( Harden  and  Grind  ) 

Length  Gage 


r^ 


0.25" 


F1G.49 


0,098'Drill '  No.40  T.D.  8c  S.W.G. 
Max. >t 

ao5"H.\\....Minr..  .J\$£, 

I* A 4 

FORGED  STEEL  (Harden  and  Grind) 
Length  Gage 


0.098"Dri/l  No.40  TD.&S.W.G. 
H -Max.---M 


-<lu 


i 


ai"R'\  u MW.----J  I  *H*fl2? 

U c J 

FORGED  STEEL  (Harden  and  Grind) 
Length  Gage 


OPERATION   27 


M> 


^?^k Max. kA  ta02'^\i 

Case  Harden  Gaging 
Surfaces 
As  Head  Diameter  B=Underfiead  Diam. 
C'Rim  under  Head  D/am. 
MACHINE Sr££L 

FIG.  45,  OP.  25 


The  Diaphragm  and  the  Tube  for  Tracers 

The  diaphragm  is  made  of  sheet  brass;  the  operations 
are: 

Operation 


Blank  and  form 
Pierce  for  tracer  tube 


The  punches  and  dies  used  for  the  first  operation  are 
shown  in  Fig.  54,  but  the  second  is  a  simple  piercing 
operation. 

The  tube  is  set  into  the  diaphragm  when  a  night  tracer 
is  used.  It  is  also  made  of  sheet  brass  and  is  evolved  in 
the  following  order : 

Operation 

1  Blank  and  first  draw 

2  Anneal 

3  Pickle  and  wash 


IIS± 


0.& 


r.^C, 


--:r  —  -5.Z5±Q03'-~->\ 
■J 


> 


r^r*2 *fmr 


0£±0.0? 
0.3"> 


47"±0.O3-- * 

Ko-,--3B\0DZ-—> 


\<-0.3" 
-OA'-n-r      _ 


'BOS' 


FI6.50 


0Z$\  &  J  \<-015' 

'"Case/harden 


[80] 


•Case  harden 


Fie.5i 


4 

Second  draw 

5 

Anneal 

6 

Pickle  and  wash 

7 

Third   draw 

8 

Anneal 

9 

Pickle  and  wash 

10 

Fourth  draw 

11 

Anneal 

12 

Pickle  and  wash 

13 

Fifth  draw 

14 

Trim 

15 

Start  flange 

16 

Assemble 

17 

Solder 

The  blanking  and  first  drawing  die  may  be  seen  in  Fig. 
56.  The  second-  and  third-draw  dies  are  shown  in  Fig.  57 
and  those  for  the  fourth  and  fifth  draw  in  Fig.  58.  The 
trimming  and  flanging  fixtures  are  illustrated  in  Fig.  59. 


OPERATION   7.      THIRD   DRAW 
Transformation — Fig.   57.     Punch   and   Die — Fig.   57.     Pro- 
duction— 4000  per  8  hr. 

OPERATION  8.     ANNEAL 
Production — 10,000  per   8   hr. 

OPERATION   10.    FOURTH   DRAW 
Transformation — Fig.    58.     Punch   and   Die — Fig.   58.     Pro- 
duction— 4000  per  8  hr. 

OPERATION   11.    ANNEAL 
Production — 10,000  per  8  hr. 

OPERATION  12.    PICKLE  AND  WASH 
Production — 10,000  per  8  hr. 

OPERATION  13.    FIFTH  DRAW 
Transformation — Fig.    58.     Punch  and  Die — Fig.    58.     Pro- 
duction— 4000  per  8  hr. 


Graduate  and  stamp  with  Maximum 
Lengths  and  Names  of  Cartridge  »«, 
Cases.  Graduation  QOfWide  by0.0l"Deep) 


>  ^"^    ftThreads  per 


0.125  Steel  Pin  driven  /h-'->1|<-SS 
■ . J -9841 


inch  USStd. 


FIG. 52 
OPERATION  28 


SHEET  STEEL  finish 

Holder  Cover 

J^-         BTh reads  per 
Inch.  USStd 

FORGED  steel  mi. Finish 
Bar  Nut 


SHEET  STEEL,  Finish  <=> 
Holder  Gikj 


Diaphragm 
operation  1.    blank  and  form 

Punches  and  Dies — Fig.  54.     Production — 8000  per  8  hr. 

OPERATION  2.     PIERCE 
Transformation — Fig.  55.     Production — 8000  per  8  hr.     Note 
• — A   1-in.    hole    is   pierced   for   the   tracer   tube,    with   common 
punch  and  die. 

Tube  foe  Tracer 

OPERATION  1.     BLANK  AND  FIRST  DRAW 
Transformation — Fig.    56.      Punch   and    Die — Fig.    56. 
duction — 8000  per  8  hr. 


OPERATION   2. 
Production — 10,000  per  8  hr. 


ANNEAL 


OPERATION   3.      PICKLE   AND   WASH 
Production — 10,000  per  8  hr. 

OPERATION  4.     SECOND  DRAW 
Transformation — Fig.   57.     Punch   and   Die — Fig.    57. 
rjuction — 4000  per  8  hr. 

OPERATION  5.     ANNEAL 
Production — 10,000   per  8   hr. 

OPERATION  6.     PICKLE   AND  ANNEAL 
Production — 10,000  per  8  hr. 


Pro- 


Pro- 


OPERATION   14.    TRIM 
Machine    Used — Small    lathe.      Special     Fixtures — Fig.     59. 
Production — 4000   per  8  hr. 

OPERATION   15.     START   FLANGE 
Special  Fixtures — Fig.   59.     Production — 4000   per  8   hr. 

OPERATION    16.    ASSEMBLE 

Production — 4000  per  8  hr.  Note — Tube  is  pressed  through 
hole  in  diaphragm. 

OPERATION   17.    SOLDER 
Production — 500   per   8   hr. 

Cartridge  Case  for  3-In.  Mountain  Howitzer, 

Models  of  1907  and  1911 

operation  1.  cupping 

Details  of  Cartridge  Case— Fig.  60.  Punch  and  Die — Fig. 
61.  Pressure  Required — 18  tons.  Production — 4200  per  8  hr. 
Size  of  Blank — Maximum  diameter,  4.905  in.;  minimum  diam- 
eter, 4.900  in.;  maximum  thickness,  0.317  in.;  minimum  thick- 
ness, 0.312  in.;  weight,  1  lb.  13i  oz. 

SUCCEEDING  OPERATIONS 
Operation 

2  Wash  and  anneal;  production,  5700 

3  Pickle  and  wash;  production,  2700 


[81] 


9 
10 

11 
12 
13 


First    draw;    punch    and    die,v   Fig.    62;    pressure    re- 
quired,  15  tons;   production    4300 
Wash  and  anneal;  production,   5700 
Pickle  and  wash;  production,  3600 
Second  draw;   punch  and   die,   Fig.    63;   pressure,   12 
tons;  production,   3700 
Wash  and  anneal;  production,   6000 
Pickle   and    wash;    production,    2400 
Third  draw;  punch  and  die,  Fig.  64;  pressure,  7  tons; 
production,  3400 

Wash  and  anneal;  production,   3600 
Pickle  and  wash;   production,   1800 

Fourth    draw;    punch    and    die,    Fig.    65;    pressure,    5 
tons;  production,   2400 


Operation 
1 
2 
3 
4 
5 
6 


DIAPHRAGM 


Blank  and  form;  punch  and  die  same  as  for  field  gun 

Shear   soldering   strip;   production,    3000 

Shear,  blank  and  form  clip;  production,   6000 

Form  soldering  strip;  production,  1000 

Solder  soldering  strip  to  diaphragm;  production,  300 

Scrape    solder    from    diaphragm;    tools,    chuck    and 

scraper;  production,   1000 

Cut   cords;   production,   12,000 

Tie  and  paraffin  cords;  production,   3500 

Solder  cords  to  soldering  strip  and  clip;  production. 

500 


5po+  , 
ForCl^7S 
Szfscrew. 


*        STEEL 


aT5"      »fcw 

Diaphragm  ~uwc  (harden) 

..  Forminq    Punch 
vOARad. 


m* 


0.4J7   V32 


Finish} '±0.005" 
10° 


■2°30'\<2.5"-~^<~2.25^{      7JX>1  STEEL 

U 4.75"--<A         (HARDEN) 

Finish  ft  0.005 
Blanking    Punch 


±^0.Q6"Rr~ 


/?/.f<* 'iF'-OH"    TOOL  STFEL  (HARDEN) 
ffJkZfi  ^     Finish  f ±0005"     ' 


Assembled 


<?.S7->\\< 


Die 

Nafe' Determine  exaersize 
oF  blank  by  frying 
forming  punch  firsfy 


TOOL  STEEL 
(HARDEN)     , 
'Finish) ±0.005 


0.0l"5heef  Brass 
\<i75^ 

0.03R: 


(FIRSTDRAW)  k.    I 
Night  Tracers  ^tjL 


For  0.375x0.875  SrH 
Filisferhead 
She/Screws-- 


■   ,.]S.      O.&fap. 

-   0.5'Ueep- 


Stripper 


^■0.25x1 5feel 
Dowel  Pin, 
Drive 


6.85 - 
'/X025Drill  \<~4U2 +$$!!'■*[  <&? 

K ■  4.694  +0.001 
Collar 

MACHINE  STEEL  (HARDEN) 
Finish/ tOOl1" 


=? 2.97"  ->\ 

FIG.  55    OP.  2 


Finish f  ±0.01" 
*\ 

*1 0.575" 

it 


(HARDEN) 
f-J375"->\  FinishftO.07 

O.Z"l^  Z  ^  &%*  jl5° 


4.8" 
Die 


<§!<■ 


is- 

Assembled    View 
8'- 

■4.75"  ■■>\ 


ForO.Z5"Dowz/Pin  ¥Ij375->\  CAST  IRON 
0. 375  deep  (harden) 

Die    Holder 


■0.375"R. 


W5~ 

MACHINESTEEL 


■>\ 


0.625" 
F*1 


H-  \*  225- V  -225  V  2.25"^  l  \*   fffiiML 
o      o      9--T-  — -  Q     o     o  1  ^ ?I^S1    S''    S\l   • 


J   STEEL 


SAW  STEEL         j     j^    am&Ffiv.      ^0.125"     Ljpp-'^ 

2,0.25 xl'SfU-SfeelTapBolh     Finish/±0.01      £..   ..^^ 


&&£?&    U  Finish/ ±007 


Key 


■02 


-8.75"- 


#15^ 


^■■-  2fvrnsin6''-->^^^\  JS 

Hj^Y  o.2"//\  -o.5"  tcti'dNbf 


s     777  ~<  R?  II  ~~t   .   // 


~A 


0.03 RH 


ti\ 


euide 

F16.  5e 


OP.  1 


TOOL  STEEL 
jj  (HARDEN) 

Finishf±0.0! 
Blanking    Punch 


U--, ^-,WI 

TOOLSTEEL(HARDEM)  Flnish/±0.01        Un" 
Forming      Punch 


J£X, 


14  Wash  and  anneal;  production,  3800 

15  Pickle  and  wash;   production,   2000 

16  Fifth  draw;  punch  and  die,  Fig.  66;  pressure,  2  tons; 
production,  1900 

17  Trim;  production,   1350 

18  Wash  for  heading;  production,   3500 

19  Heading;  punch  and  die,  Fig.  67;  pressure,  600  tons 

20  Punch  primer  hole;   production,   2800 
20-A    Rough  head  and  drill  primer  hole 

21  Broach 

22  Burr  out 

23  Point  anneal 

24  Tapering;  die.  Fig.  68;  production,  1800 

25  Finish   head 

26  Stamp 

27  Finish  trim;  length  gage,  Fig.  49 

28  Inspection;  gages  are  same  as  used  for  field-gun 
cartridge  case  except  length  and  cylinder  case.  Fig. 
67 


Cartridge  Case  for  3-In.  Gun,  15-Pounder, 

Model  1898-1902 

operation  1.  cupping 

Details  of  Cartridge  Case — Fig.  70.  Punch  and  Die — Fig. 
71.  Pressure  Required — 73  tons.  Size  of  Blank — Maximum 
diameter,  8.505  in.;  minimum  diameter,  8.500  in.;  maximum 
thickness,  0.469  in.;  minimum  thickness,  0.459  in.;  weight, 
8.125   lb. 

SUCCEEDING  OPERATIONS 
Operation 

2  Wash  and  anneal 

3  Pickle  and  wash 

4  First    draw;    punch    and    die,    Fig.    72;    pressure   re- 
quired, 47  tons 

5  Wash  and  anneal 


[82] 


8         Pickle   and   wash 

7  Second   draw;    punch   and   die,   Fig.   73;   pressure   re- 
quired,   45    tons 

8  Wash   and   anneal 

9  Pickle  and  wash 

10  Third    draw;    punch   and   die,   Fig.    74;    pressure   re- 
quired,  42   tons 

11  Wash  and  anneal 

12  Pickle   and   wash 

13  Fourth  draw;   punch   and  die,   Fig.   75;   pressure   re- 
quired,  31   tons 

14  Wash    and   anneal 

15  Pickle  and  wash 

16  Fifth    draw;    punch    and    die,    Fig.    76;    pressure    re- 
quired,   26   tons 

17  Wash  and  anneal 

18  Pickle  and  wash 

19  Sixth    draw;    punch   and    die.    Fig.    77;    pressure    re- 
quired, 15  tons 


34  First  point  anneal;  approximate  heat,  1300  deg.  F.: 
6  min. 

35  First  tapering;  die,  Fig.  81;  pressure,  45  tons 

36  Second    point    anneal 

37  Second  tapering;  die,  Fig.  82;  pressure.  45  tons 

38  Final  trim 

39  Finish-turn  head 

40  Stamp  head;  pressure  required,   15   tons 

41  Final  anneal 

42  Inspect 

Cartridge  Case  for  3-In.  Gun,  15-Pounder, 

Model  1903 

operation  1.  cupping 

Details   of   Cartridge   Case — Fig.    83.      Punch   and   Die — Fig. 
84.      Pressure — 60    tons.      Disk — Maximum    diameter,    9.380   in.; 


® 


tool  STEEL,  (Harden)  FinlshJ±  0. 005" 


COLD-DOWN STEEL finishfiQOi"  _.      ,  ^  n 


Clamping   Screw 


raw         Die,3^  Draw 


If-' 


I.Z5 SJhreads  .^nt-jri 
(perlm^SUjX^       J>.ft"Tap 

'     '°-°  l"Deep 


MHCH.5TEELfinishft0.0l\<-^% 

Punch  Guide  Holder 


„<i  0.187  (ig)-    * 
©     ^pzd&i'J    Y     ^Thread 

S    u-..-aapr—  -3    _ 

»©1^1        SJ&L     .    ,   TOOLSTEEL/HardenjFinishf^l"  T00LSTEEL<Hard^ni5hfW? 

ciSTiROHWl"QW(i)Top$td      F,nishp0.005  |§.      *  fy     JW'gDrill  „ 

Die   Holder  Collar  +^^.^03  R.  •'.       OfiZ&td. 

,,T,       ,  FIG.57  Night-tracer  Tube,  21dand3r^  Draw  ^\  Q  ^t^^^f— ^Thread 

MU&td                     .     .    P^ches  and  Dies                           C\  BTTLb*  Ww£^'JJ 

tl  /  lnc\U£-5fd  W7?m"  OPERATION  ..4  &  7    ^j?  W  *- M  ^-^->Jrf— — 

%.^^pfoi.,.Ty  l6Threads*\rb  ,,,    ^^  §§ plw*^  ,  «PPn>*  VX>LSTEEL,(HarJen)Flnish^ 

^fe*      ^A-//B-/^/C-/"^r^.    Punch.3^Draw 
^^^^     0neA-Z5"B'l"     0,-0.75" 3&Drzm 

m§J^  m,STEEL,Fini^C.O,"        *4^%J^       U-F?*** 

'  inch-guide  Ring  ^SS«f  reg^      Night  Tracer 


TOOLSTEEL,(Harden)FinishpH0l" 
Punch  Guide,  2*^  Draw 


'^'+■1  SStd.Thre, 


Finishf+QOI 


0^rTk^ 


'Std.  thread 


l"  r,0M"TaPStd. 

o 


COLO-ommsTEEL,FmishftWf  mLSTEEL,(Harden)FinishJ±aOl" 
Clamping  Screw  FVjnch  Holder 


Assembled  View  %^..W^..    .  J 

CUST  IRON  i  0.01" 

Die  Holder 
One  A-0.87",4*J>  Draw        *  v. 
8m/*Q.7i:5>-hDraM         |§  £ 
TOOLSEELJHarden) 
Fin>shj±0.0l" 

0>% 


^£38!  A 

7MSTEEL,(Harden)FinishJ±Q0l"    ^  I  ■  \\/JS7f/gZ0rhreads 

Collar  f""     per  Inch, US.Std. 

HUCH.STEEL,  Finish jtQOI" 

MT+0OW*.    £  </S>-Q!87$"ML?<;'  Punch -guide  Holder 
C  /^r»  3  IHferTrimminq 

^LSTEEiJH^nnish/mf     tSKSw 

B   Punch. 4t6  Draw       „„,,„„    . 


TO0lSTEEL~(Harden)FinishJiQ.0l" 
Punch.  Sin  Draw 


S5C 


J& 


«• 


•fl«?'yf. 


l*--325* 

T00LSTEEL,(Horden]Ffnish/±0.0l" 

OneA=0.87'B-l,4+*Drow 
One  A'0.72"  B-0.85"  5tfDraw 


rW2"    y-(        ^1     A 
J  V   rZ6Z5^pPfox. 

^AfterTrimming 
SHEET  BMS5,  QOl'Thick 

TracerTube,5+-b  Draw 


Punch  Guide      OPERATION  I0&I3 
FIQ.  58    4tt>  and  5th  Draw 


Trimming  Operation  Flange  Operation 

ASSEMBLED  VIEWS 


^ 


OneA-084"  &Q.8',4i*Draw 

OneA-0.69"  B-0.65 "5* 'Draw 

tool  STm/Harden)  Finishf±  01 

Trimming  Bushing 

miUf     om*\  r(iz)" 

Ream  ii^.fc  -fe^iJ-^i 


•-0000"  r -MBftdf-  ■  - "  ">1 


ILd  *B     jj     I 

5W^        m'DrilF    m 

mCH.STEEL,Finish/±C 


Q5IZ-*  kl/ 
Flange  Bushing, 5tt  Draw 


ZOTh reads  per 


One  A=0.84"; 4-** Draw 
One  A=Q69',5t!>  Draw    . 
HUCH.STEEL,  Finish/ ±0.01 

Spacer 


/^J\  i_'y^TTml — it — I     *>        ]      fff*»  - 


HUCH.STEEL,  FinishftOOl" 

Holder,  4^>  Draw 
FIG.  59  Fixture  for  Trimming  and  Flanging 
OPERATION  146c  15 


20  Sixth-draw  trim;  trim  off  20  per  cent. 

21  Wash   and   anneal 

22  Pickle  and  wash 

23  Seventh  draw;   punch  and  die.   Fig.   78;  pressure  re- 
quired,  10   tons 

24  Seventh-draw    trim 

25  Wash  and  anneal 

26  Pickle  and  wash 

27  Eighth  draw;   punch  and  die,   Fig.   79;   pressure  re- 
auired,   7  tons 

28  Eighth-draw  trim 

29  Wash  for  heading 

30  Heading;  punch  and  die,  Pig.  80;  pressure  required. 
850  tons 

81         Rough-turn  heads  and  drill  primer  hole 

32  Broach   primer   hole 

33  Burr  out 


minimum    diameter,    9.375    in.;    maximum    thickness,    0.438    in.r 
minimum  thickness,   0.428   in.;  weight,   9.25  lb. 
SUCCEEDING  OPERATIONS 
Operation 

2  Wash  and  anneal 

3  Pickle  and  wash 

4  First    draw;    punch    and   die,    Fig.    85;    pressure   re- 
quired,  45  tons 

5  Wash   and   anneal 

6  Pickle  and  wash 

7  Second  draw;   punch   and  die,   Fig.   86;   pressure,   40 
tons 

R         Wash  and  anneal 
9  Pickle  and  wash 

10  Third    draw;    punch    and    die,    Fig.    87:    pressure,    30 
tons 

11  Wash  and  anneal 


[83] 


12  Pickle  and  wash 

13  Fourth   draw;    punch   and   die,   Fig.    88;    pressure,    30 
tons 

14  Wash   and   anneal 

15  Pickle  and  wash 

16  Fifth  draw;  punch  and  die,  Fig.  89;  pressure,  20  tons 

17  Wash  and  anneal 

18  Pickle  and  wash 

19  Sixth    draw;    punch    and    die,    Fig.    90;    pressure    re- 
quired,   10   tons 

20  Sixth-draw  trim;  trim  off  20  per  cent. 

21  Wash  and  anneal 

22  Pickle  and  wash 

23  Seventh  draw;  punch  and  die.  Fig.   91;  pressure  re- 
quired, 8  tons 

24  Seventh-draw   trim 

25  Wash   and   anneal 

26  Pickle  and  wash 


27 

28 
29 
30 
31 
32 
33 
34 
35 
36 
37 
38 
39 
40 
41 
42 


Eighth    draw;   punch   and   die,    Fig.    92;   pressure,    5 

Eighth-draw  trim 

Wash   for  heading 

Heading;  punch  and  die,  Fig.  93;  pressure,  1050  tons 

Rough-turn    head   and    drill    primer    hole 

Broach 

Burr   out 

First  point  anneal 

First  taper;   die,   Fig.   94;   pressure,   50   tons 

Second   point  anneal 

Second  taper;  die,  Fig.  95;  pressure,  50  tons 

Final    trim 

Finish-turn   head 

Stamp 

Final  anneal 

Inspect 


^Long- 
Solid  braided  I 
white  Cotton  I 
CordNs3i  ■- 
Dipm  hot 

-Paraffined 

1  Long- 


hardSolderZ  -  -  ■ 


Q5"Drill,0.75'Deep 


Section  A-A 
1£y  sW 


4 Crimps,        \      %    , 
Equally  spaced  -^  .Jr  0M'*\  ±  0005" 


r -^-as 

TOOLSTEEL,  (Harden)  Finishfy±u005 
Third  Draw  Punch 

FIG.  64 
OPERATION  10 


Third  Draw  Die 


N  ■  Seat  for  110  6r Fkrcussion 
Primer  Rough  Bored,  Oils' \ 
Oiani.,  Mandre/ed  to  044 " 
Diam.  finish  Bore  Taper  _ 
■Omtfat  large  End.      \;  y 
Taper  OOOZ'in  Diam.  per 
Inch  of  Length 


||  5Threadsper  /Taper6age    ^OS'DrillM'Deep 

an  inch.usstd)  *  _  _JZJ:  :   **■. 


Stamp  Name  and  Model  of 
Howitzer,  Place  and  Year  of 
Manufacture.  Letters  and 
Figures  OOZ'Deep 


w  Remove 
—  VX$>&-\sharp 

•  '  ™  Corners 


ft 


,k 

■  I0.5---. 
15.43/(15%) 


CfSRrirj) 

1    b'      TOOL5TEEL,(Harden)Finishfgt0005 
Fourth  Draw  Punch  fig.  65 

OPERATION  13 


Fourth  Draw  Die 


.  v  Remove 

p/  T  $5"-?.-sharp 
-^j~k  Corners 


T0OLSTECL,(Harden)FinishJgiQOQ5'       _,_  __ 
r-.^.,     r,  r>  rlo.66 

ifth  Draw  Punch  OPERATION  16 


mLSTcFL,(ndrden)FinishJg±0.005' 
Fiflh  Draw  Die 


Ik'StampName  of  Cartridge  Case,  Operation, 

Place  of  Manufacture  and  Date  (Year) 
Y- Stamp  Name  of  Cartridge  Case.Operation.Diameter  I 

of  Die,  Place  of  Manufacture  and  Date  (Year) 


k--4SSl'(4%f-A< -4.5"  - 

!•— mf(9lf- > 

Cupping  Punch 


5Threadsper  /'Taperbage 


3?       k 

— *  Remove  sharp 
;Q05*Cprners 


W5*m. 


tool  Stul,( Harden) 

FinishJg*-0005' 

Punch. 


TOOL  STEEL,  (Harden)  Finish <fgtQ005 

Fie.  6i 

OPERATION  I 


Cupping  Die 


FIG.  67 
OPERATION  19 


-6.403' 


,      ,       Remove  sharp 
r^l^Y    '.Corners 


T00LSTEEl,(Harden)'  ,—«  %-...R„„w 
Finishjgmi'1^  F0R%%EL 

finishf±0.0t' 
Shrink  on  offer 
Die  is  hardened 


■5.158'— >m& 
StampNameof     Body  Gage  for  3-in  Howitzer  Case 
Cartridge  Case,  , 

Operations:  Die,  Mis- 


place ofManufacture 
*]  and  Date  (Year) 


k SZ'—^rrfr 

k iz"  ^ 

Body  6agefor3B-in.  Howitzer  Case 


k~4.937'(t§"----  "•-*:  ; S-- H 

k mi'tii) .-J 


2       Vm^A    'TopSection 
TOOL  STEEL.(Harden)FinishJgta005' 
Tapering 

FIG.  68 
OPERATION  ZA 


TOOLSTEEL,(Harden)FinishfgiQ005' 
Second   Draw  Punch  Second  Draw  Die 

FIG.  63 
OPERATION  7 


k 6.48"---M 

Body  Gage  for4.7-in.  Howitzer  Case 
Stamp  Name  of  Cartridge  Case,  Sage,  Dimensions 
gaged  Place  of  Manufacture  and  Date  (Year) 
FIG.  69 
OPERATION  28 


[84] 


34/3  Mar.       ,,£.   %i05'uax 


Chamber 
- 20.02+002 

y////////////////////////////////A 


QQ?5^  fc 


\'jX" 


jrfir** 


IT" 


ifit»htofCase  675&s  Zlll^zi-TZ""^. ■/-  X- 

£  "Charge  5lbs.   U —  gf9? 


Case 


«■  %£ *»^- isy^* 


■JKP5-*'    /        5RrInch-USSfcL 

*--5.5~tA    Thread  , 

<?<#».+ *//■*&  Charge  5lbs.  * —8Ff ■/-**  ** 

— r>nA    I  v  x  Do  not  harden  this  end.        S       Stamp  Name  of  CartridgeCase^  %  ^83^00)0-0003-^ 

^£l%  Tbbe  turned  alter  otherend  Operation.PlaceofManufacfureir^—'^ry\  ('^(STS'WfffiX 

has  been  hardened  and  around.       and DatefYear). 
TOOLSTEEL(Horden)  Finish Jgt-tQ005" 

Punch  FIG.76.0P16 


3fl 


t5t 


^\ooi"i^ 


Buff  inside  of  Case  before  Soldering. 

Solder  with  Soft  Solder  alter  Assembling 

Distance  Wad. 

Soft  Solder  Composition  .- 

3 Parts  Tin.3 Parts  Lead,  I Part  Bismuth  ' 

Note:-  This  Cartridge  Case  is  used  in  15 Pdr     Cartridqe  Case 

Guns.Model  of  l902,Bethlehem  Design  3 

Diaphragm  and  6uns  Model  of  m.Driggs-Seabury  Design 

FI6.70      r 


o 


■5 


*^~  7^-7  »  far*** 


TVOLSTai(Harden)Finishfy!Q005" 
Die^C 


Donot  harden  this  end.' 

lobe  turned  after  other  end  Operation.Place  of  Manufacture  —  *«J"  i        005" *apj«__  V&» 

has  been  hardened  and  ground.         and  Date(Year).  ^s  <*'* 

TOOL$TEEL(Horden) Finish fy!Q005"  (  TDOLSTEEL(Harden)FinishfylQ005" 

Punch  ^^./FIG^OPte  0i« 

"*1  " 


"     K?5U       y.'37^"       ^  Stamp  Name  of  CartridgeCase.\   <§      *S 

Do  not  ha/den  fhisend.  %"?%'"?  <??_..%  %  W 

Tbbe  turned  after  other  end    UaWe°7-  '  pfyjffl 

has  been  hardened  arid  ground.  <Qsk      jr«k- £5* *  Ss 

TOOLSTEEL(Harden)FinishfyW005  «   («--«--• 12.55"-- ->l 

Punch  „„  ,,  rt0,     TO0LSTEEL(Harden)Finishfg!0O05" 


Y...575."..m^l55UrInch-   . 
--J< •  - --J&y-- * USStd.Thread.  | j§|*^&?£»^£jgfo 


K ^'--r' 

|«. -.'■•--335 

Donot  harden  thisend.    ''  Stamp  Name  of CartndgeCase...y 

lobe  turned  alter  other  end  Operation,  Place  of  Manufacture     i*\         QOi~">n-Aii 


^Ye6^±\^sthff 


FIG.71.0P1 


|«i I...//C  >'...'. J  'Stamp  Name  of  Cartridge  Case, 

(h  not  harden  mend.  Operate  Place  of  Manufacture^ 

Tobeturnedafterotherend  "."<*  Date  (Year).  ^ 

has  been  hardened  and  ground. 

TOOL  STEEL  (Harden)Finishfa  iQ005' 

Punch  005-^5.995   ^ 

FIG  72  OP 4.  TOOLSTEEL(f/arden)Rnish&0005 

XjFrttoTaper  Gage 


has  been  hardened  and  ground.  and Date(Year). 

TOOL  STEEL  (Harden) Fnishfg  tQ005                     TOOL  STEEL  (Harden)Fin<shfgtQ005" 
?uncb»f;  c?&>5"Dr,ll        FIG.78.OP23    , Die     ,^» 


K —  ..jr/^.....;.-:....>u.-''.:f5?,'..>ix     ■-        ^  ^Ljfeib     »<^y 

C £__4ei« "-/"•3wa*vf  rlrf'%M 

Do  not  harden  this  end'  0  /        frljr      *  .^'"^ L      rKW™ 

Tobeturnedafterotherend  Stamp  Name  of  Cartage  Case..-  »TU      «%V   Wj 

has  been  hardened  and  ground.  Operatbn.Place  of  Manufacture    ^ 


Do  not  harden  this  end.  Stamp  Name  of  Cartridge  Case,    *.     L 

Tobeturnedafterotherend  Operation.Place  of  Manufacture*.1^  V 
has  been  hardened  and         and  Date(Year). 
ground. 

TOOLSTEEL(Harden)Fnishf3tQ005"  ^^^M^^jf^S 

Punch 


TOi  STEEL(Harden)FinishfgiQ005" 


FIG.73.0P7 


Die 


<Q6Z5"Dnll 


. .  .jS  7Tj  ^l"Dia-gPerInckuJ5rdThrr<id 


^^''  \?#^?6%l6"^%''^&"^%''^6''^26^?6^fc      QxomwNSTt 


u 

T0OLSTEEL(Harden)tlnishJfy!~0005" 
Punch 


%55" 

0"SteelPnsO25iO5O" 


nm© 

TUt^f       T00LST€EL(Harden)Fnish/gTlW5' 
-JX  1  Head  Pin 


«H* 


FIG.80.OP3O 


TOOLSTEEL(Harden)Finish/g-im"  FirishfcQOl  "/StampNameofCartridgeCase._ 
Die  Ear 


3"* Section 


Do  not  harden  this  end.       '        Stamp  Name  of  Cartridge  Case. 
Tobe  turned  after  other  end        Operation.PlaceofManufo 
has  been  hardened  and  ground.    ana DatefYearJ. 
TOOL  STEEL(Harden)  Finish  fa  10005 
Punch 


IS  ">     4"'5eetion       >      i'^iection     \     ^Section    \ 


OILLL     f 

fQ01"/Si    . 

\r      /  Operation.  OieNumber.  Place of 

—-. Manufacture  ana 'Da/efYear). 

Ist Section  > 


062S"Dr,/l.075"Deep 


FIS  74  OP  10         T00LSTEEL(Harden)Finishf*QO05" 


i 


ill 

Ir^.f.HJ ^.?.^j. 


u 

Do  not  harden  this  end. 


■665"--- 


■  J,.. 


■  665"- 


102 


4mSectbn 


23.95 

TOOL  STEEL(Harden)Fimshf9t0.005" 

TaperinaDie_ 
" "3'^Sec'tbn  \"   T"SSec'fl'nr\.  P' Section. 


7ri 


/     \0B—*y    ^^rlnch 
■11"--/—- *k-- -35"/- -^USStd. Thread.     %  W-/0?3"+jM)*d.003yii;$. 

-/-i65"~ -/--J         rLb£-^ 

Stamp  Nameof  Cartridge  Case       y  J^s//y/yA  r  -Olff^Ot 


FIG.8I.OP35 

Stamp  Name  of CartridgeCase 
Operation.  DieNumber.Place  of 
Manufacture,  and  Da/rOkir). 
i 


Tobeturnedafterotherend      Operation.  Place  ol 'Manufacture *?f|  U/7?  "W0J'^^°^ 

has  been  hardened  and  ground,  and Date(Year).  ^  U^ ■  10.17 'J—  — ; "^ 

TWLSTECL(Horden)Finishj:9tQ005"  T00LSTEEL(Harden)F,nish/giQO05 

Punch  Di3 

F!G.75,OP13 


->t< -662"— -^ 6.62"—  -^ht^*"*i 


•/JKK- — ?5f"—— H 

T00LSTEEL(Harden)Finishf9-t0O05" 
Tapering  Die 


FIG.82.OP37 


[85] 


e&ymJ 

"U  V*i  '£&3?"  .  tough  bored  Q375"dkim.  tfandvkct  toQ44 


/  *-/2J8!~**fJ8t*-— £$*■■*? 
-■21.5"- *l 

Punch 


FJ6  89,  OP.  16 


Tapering     Die    (?*» OPERATION) 
FIG.  95.  OP. 37 


[86] 


The  operation  lists,  dimensions,  dies  and  other  infor- 
mation on  the  other  cartridge  cases  up  to  6  in.  in  both 
the  gun  and  howitzer  types  are  as  follows : 

Cartridge  Case  foe  3.8-In.  Howitzer, 

Model  1908 

operation  1.  cupping 

Details  of  Cartridge  Case — Fig.  107.  Punch  and  Die — Pig. 
108.  Pressure  Required — 50  tons.  Dimensions  of  Disk — ■ 
Maximum  diameter,  6.005  in.;  minimum  diameter,  6  in.;  max- 
imum thickness,  0.431  in.;  minimum  thickness,  0.421  in.;  weight, 
3.739  lb. 

SUCCEEDING  OPERATIONS 
Operation 

2  Wash  and  anneal 

3  Pickle  and  wash 

4  First   draw;    punch   and   die,    Fig.    109;    pressure    re- 
quired,   30    tons 


5  Wash  and   anneal 

6  Pickle  and  wash 

7  Second  draw;  punch  and  die,  Fig.   110;  pressure,  20 
tons 

8  Wash  and  anneal 

9  Pickle  and  wash 

10  Third   draw;   punch  and  die,   Fig.    Ill;   pressure,   16 
tons 

11  Wash  and  anneal 

12  Pickle   and   wash 

13  Fourth  draw;  punch  and  die,  Fig.   112;   pressure,   13 
tons 

14  Wash  and  anneal 

15  Pickle   and   wash 

16  Fifth   draw;    punch   and   die,   Fig.    113;    pressure,   10 
tons 

17  Fifth-draw  trim 

18  Wash   for  heading 

19  Heading;  die,  Fig.   114;  pressure,  1000  tons 

20  Rough-turn    head   and    drill    primer    hole 

21  Broach 

22  Burr   out 

23  Point  anneal 

24  Taper;  die,  Fig.  115;  pressure,   20  tons 


Stamp  Lot  No  of  Ammunition  OO/berp  0J0jTap-4Jfr//r.l/SSfd     -A\<005''Q0l''  +1)000' 

.   ~? /  Thread,OJS%ep_  -y-lUsyft  jW"-0MZ" 


0.000" 
Q045"-a00A 


3 FilisterHead Screws  eaually  spaced.       mnireS7M 

H/- ■■■■-&*■ - *Mff0Ol 

\H-CW7U)^>\      ,;         ,    U  Cup,  Rate 


tk      m        TuTTmli  r   ,/  ///>/•  ^^mS+OOOO'-u     '*OZ"f0OOS"*'FinishfApprox.O2"k>ck from 'shoulder 

Stamp  Name  and  Model  of Hmitzer  Seat for 110 brain'     0.14  -/£wc"T  •*"                                        »+0000 

and Ptaceand  Year  of  Manufacture.     Percussion frimer.Pough  |  I-4 " "j« 

Letters  and  FiguresOOf Deep.        *  Bored 03JS"Diam.MandreledtoQ44" \^ j${ 

,    ,  '001'  ems 

«-/.65tr 


....W-. 
SJS---' 
■10.15"- 

U-- ---/ois"ooo/' 

TOOL5TEa(Harden)FinishJ[^^0i 
Cupping     , 


T00L5TEELfinish/-L 
Punch  Holde 


FIG.II3 


T00L5TECL  (Harden) ]hnishfy?0005" 

Tapering  FIG.  115 


[87] 


25  Finish-turn  heads 

26  Drill  for  screw-eyes 

27  Tap   for  screw-eyes 

28  Stamp 

29  Final  trim 

30  Inspect 

Cartridge  Case  for  4.7-In.  Gun,  Model  1906 
operation  1.  cupping 

Details  of  Cartridge  Case — Fig.  116.  Punch  and  Die — Fig. 
117.  Pressure — 65  tons.  Dimensions  of  Disk — Maximum 
diameter,  8.630  in.;  minimum  diameter,  8.625  in.;  maximum 
thickness,  0.505  in.;  minimum  thickness,  0.495  in.;  weight, 
8.987  lb. 


SUCCEEDING  OPERATIONS 


Operation 

2 
3 
4 


9 
10 

11 
12 
13 

14 
15 
16 

17 
18 


"Wash  and  anneal 

Pickle   and   wash 

First    draw;    punch    and    die,    Fig.    118;    pressure,    60 

tons 

Wash   and    anneal 

Pickle  and  wash 

Second  draw;  punch  and  die,  Fig.   119:   pressure,   45 

tons 

Wash   and   anneal 

Pickle  and  wash 

Third   draw;    punch   and    die,    Fig.    120;    pressure,    40 

tons 

Wash  and  anneal 

Pickle  and  wash 

Fourth  draw;  punch  and  die,  Fig.   121;   pressure,   30 

tons 

Wash  and  anneal 

Pickle   and   wash 

Fifth    draw;    punch   and    die,    Fig.    122;    pressure,    25 

tons 

Wash  and  anneal 

Pickle  and  wash 


19  Sixth   draw;    punch    and    die,    Fig.    123;    pressure     20 
tons 

20  Sixth-draw  trim;  remove  20  per  cent. 

21  Wash  and  anneal 

22  Pickle   and    wash 

23  Seventh  draw;  punch  and  die,  Fig.  124;  pressure,  15 
tons 

24  Seventh-draw  trim 

25  "Wash  for  heading 

26  Heading;  die,   Fig.  125;  pressure,  1400  tons 

27  Rough-turn   head  and   drill   primer  hole 

28  Broach 

29  Burr  out 

30  Point  anneal 

31  Taper;   die,   Fig.   126;   pressure,   45  tons 

32  Finish-turn   head 

33  Stamp;   pressure,   15  tons 

34  Final   trim 

35  Inspect 

Cartridge  Case  for  4.7-In.  Howitzer,  Models  of 

1907,  1908  and  1912 

operation  1.  cupping 

Details  of  Cartridge  Case — Fig.  127.  Punch  and  Die — Fig. 
128.  Pressure — 90  tons.  Dimensions  of  Disk — Maximum  diam- 
eter, 7.105  in.;  minimum  diameter,  7.100  in.;  maximum  thick- 
ness, 0.465  in.;  minimum  thickness,  0.455  in.;  weight,  6  lb 
9  oz. 


Operation 
2 
3 
4 

5 
6 


SUCCEEDING  OPERATIONS 

Wash  and  anneal 

Pickle   and   wash 

First   draw;    punch   and    die,    Fig.    129;    pressure, 

tons 

Wash  and  anneal 

Pickle   and   wash 

Second  draw;  punch  and  die,  Fig.  130;  pressure, 

tons 


5  0 


4o 


■A  'f05'-'cW5 


•^Harden  7 Appro*.  k/j2h//  • 


r* ~r-atS---M  I 


^W-0675"/f  Yq05;Ru,.. \mz*WQ"_ \J^X°"j ' 
^mV-}75"**5"~>MW5^  ¥  1.125"  l-         n#.      "^/"  W      J? 


SHEETBRASS 
Diaphragm 


3^  Draw 


V       SoftSolderComposition:-5 Parts Tin^&rtsLeadJRirtBismuth  xi 


Capacity 25/Cuhic  Inches 
Wight  of  Case  7875 Lbs 
Weight  of  Charge  584Lhs. 


■j.   fT 


££r S7^  TDOLSTZEL(Harden)F,n,d,/gl(XW 

TOOLSTEEL. Fnish/glOOOS"  FIG.I20  3     Dra" 

^rd-n 

Y Kitt'mz* >| 

h 58?"-r-;,-->\        .1 


*  I7Sk-375"*h-  325  *<  -  ■  -575"  ■•>)  /V--7* 


U 15.5- 

TOOLSTEEL. Finish/ g  '& 


TOOL  STEEL(Horden)Fmshfg  -0005" 
4th  Draw 


iMenterofCrwtyfote^Wf'  U l452» ----"----, >K  J'  >\  /^Vl&Sr§±\>-QB6'  4*Draw 

I  IfiBfJmto/tieU, Kgf-^SS.  «~- >^  ChrfrjaeCasefobecnmped 


FIG.I2I 


C02"Deep.filled*ithRedlbntt  Seat  for  110  Grains  ftrcussion  Primer 

IndicatesthaflOZofthe       Rough  BoredQ575"DamMandrelcd  toQ44" 
Shrapnel  ire  fitted  mth  a     Finish  Bore  fopers  0.6%  Large Fnd.  u-.... 

ShellTracer  Taper 0007 'in D/am.  per Inch in Length      | 

'  ForQfiflatFil. 

\yV*  025"hpStd. 
_±  $  M'Deep" ', 
5frlKhUS,     *''"',     W5W^~  P 

Stdim  -*  75^-175  *<3375*     Vm"  U I2.5t0.002---- - - A 

W--S.5 --'!*<— -5—  -A               FIG.II7                T00LSTEEL(Harden)FinishfytQ005 
TOOLSTEEL.Fmishfg  10005  .  ,,,,.„,,    Cupping I 

,£u^,   *  r069»i5"Mf         .1     er%: -OP- -Wft  H 


>t 

'  atfburlhntsineachoftheTwoGrooves.  „  +\*044 

Crimps  located  45"apart.   067$**  ■--  Harden  12 'faro* ---■  4j> 

mo0esmlT^e&M®g$  «*&■■  f  ■  -115%- 


-*i  LTfU  375">*--475"  <+*  •  •  -  725"  -  •  VU\«, 
K- - 185" •; v 4" 

TOOLSTEEL.Fmishfg  1Q005 

Operat^.flaceof  5+h°raW 

Manufacture  and   0625"DrillfPeep 


V I02"--; •«=-—  — -H 

TOOLSTEELlHardenJFnish/g  -'0005 
5fK  Draw 


FIG.  122 


0525  Drill l"Dm..^0en4^^V  m      m'jf. 


W^jU^l75^375"^2.75W75^:m'K 

TOOLSTCEL,RnishfglOW5"  FIG.II8 

Ist  Draw 

±0625" 


K- 1244- •-- *r  SharpCorner 

TV0a7m(Harden)Fnishfy-,a005''  on  all  Dies. 

Draw  „ 


\<-55"     ■ 


ri&-jft     k. ■■■82:- 

-x/V-^"         '         T00LSTEa.(rbrden)FInish/gW5' 


TOOLSTEEL ,  Finish fg  10005" 
6th  Draw 


to 


:■■/•'; 


— L025W02- 


mmi 


-A  175^-575  ->*-  -4"-  -^-5'--  X069'- 


tuts** i"mp 

H--55"->i<- 


-*&,-- --Harden  22" Appro*  - -+?     •SFj 


FIG.I23 

*<z0575" 


6+hDraw 


^t~....jrc~tL.  -■>4<--  -  - -7^  ~-  -  .->-J 

TOOLSTEB. .  Finish  fy  -'0005 
2nd  Draw 


waj^— ga 


FIG.II9 

FMnUSMThd,^^ 


-—10" >K--- //"- — :«ft 

- 23" " ~---A 

TOOL  STEEL,  Finshfy -'0005 

7  Draw  Stamp  Nameof&rtridge 
a  „  ^r^j  FIG.  124  A  Case.0peration.Pfaceof '' 
StampNameofCarlndv  Manufacture  and Dateifear). 

Lose.Vperomn.nace  of 


,ESf^       a25yeam.Q3Veep': 
L25K^hj»^,,2U.  •»///k  *i//A     mX-SfEElfHarden) 

J*.* ■" 1975"-  — ~4iM        Fnish/a  SCW5/ 

T0CL5TEEL(Harden)F,n,shfyi0005  Head  Rn 

Head  RjncK         _,  _  ,__  . 
FIG.  125  A 


H Of--  J» 2J 

70a  Jr«Z  (Harden)Finish/g  107X75 

2nd  Draw 

I                         ^^/-/i/i^vr^  Case.Operation.Hace  ot 

P f-— 825*0002 *]  *!,,„„/„<;,«(  and  MM. 

MtOtlNE STEEL  ,i       S      ,,.//  .       »J  *      ,  \       t* "  ~"'2S?fS!l  i 

U  ■  fef''f  wyw"  ^"T  r* i65"----~---'~-',\KM4CHWEJriTL, 

.     ..,  497-:^    -W^      ■  7WLSmL(Harden)F^fymf'^JlOOI 
«/ *l.  lj..j.._  Ring 


Fimsh/iiVl"  Wfiyv. 

Bolt  ^^If/J-W/"-;, 


TOOLSTEEL  (Harden) Finish  fg  10005* 

7*- Draw 
FIG.I24B 


Heading. 
FIG.I253 


*i//5T. 


TOOLSTEEL  (Harden)Fmishfyl0O0S 
Tapering 

FIG.  I 


[88] 


8 

Wash  and   anneal 

18 

9 

Pickle  and  wash 

19 

10 

Third    draw;    punch   and    die,    Fig. 
tons 

131; 

pressure, 

30 

20 
21 

11 

Wash  and  anneal 

22 

12 

Pickle  and  wash 

23 

13 

Fourth  draw;  punch  and  die,   Fig. 
tons 

132; 

pressure, 

20 

24 
25 

14 

Wash  and  anneal 

26 

15 

Pickle  and  wash    ■ 

27 

16 

Fifth   draw;    punch    and    die,    Fig. 
tons 

133; 

pressure, 

15 

28 
29 

17 

Fifth-draw  trim 

30 

Wash  for  heading 

Heading;  die,  Fig.  134;   pressure,   1350  tons 

Rough-turn  head  and  drill  primer  hole 

Broach 

Burr  out 

Point  anneal 

Taper;  die,  Fig.  135;  pressure,  30  tons 

Finish-turn  head 

Drill   for  screw-eyes 

Tap  for  screw-eyes 

Stamp;  pressure,  15  tons 

Final   trim 

Inspect 


Cupping  &  \t  Draw    FIG.  128  &  129 

tool  steel  „       OP.  l,&  4 

finish  fa  tO.OOS         ,    ^  „„„ 


>k- /6" 

2/.S"- --- 

5th    Draw.  TOOL  STEEL 

F/nishfqtO.0051'      ..       FIG.r33,0PI7 

0375"^-—-  $    -x 


SFffs 

^SMScnmeauo/iy  h4  4167  #£)■  -  -*| 
Spaced--,  .  i  J* -£*"""  VI2-\ 
0.25"Sfd.Tap...    '-W\\%.%%- 


C UP  PLATE 

Mach  Steel,  Tint  , 
^^■3-0.25"x0.75*Sfd. 
\U  ^fi/'sterHead 
>!  :  "*l  r*f$£k  Stee/Screirs 


1 

3 1 


*Z25~_zl7S 

%-■-£-- >i 

-JOS'- -J 

21d   Draw    . 
TOOL  STEEL  finishfg  W05 
FIG.I30.0P.J 

"jprm.  > 


0.05% 


^-\0K"H. . 
hJ 

-12.44"-— W. 

-J2.5t0.0021'- J 

Cupping 
7i?0Z  STEEL,  finish fgta005"Harden 
FIG.I2S,0P.I 


Punch    Holde r,  /W«  5722Z  f/nishftO.Oi 


k/7^- 


70<?Z  STEEL.  Fnish/qtO.005 Harden 
FIG.  129, -1 OP. 4 


->!/ 


Y- -£5'--*4*---~  7"  *\  K — 5.5*— ►-W-- -//- ->| 

< /25-' -J  k /£/- s4 


0.05/1::. 


3^  Draw,  72><?Z.  .S722Z. 

fiWshJgtaOOS"  FIG.|3I0R1I 

,f* ---/7.S75-' 

r£.&4SE — -/7 

fit 

9>t      ^if"-"""   3«DSECTI0N  2»"SECTI0N    ISTSKTION 


4th  Draw  7i?<?z  5ffif/. 
Finish fgta005h 
*]    «^/HG.I32,0RI4 


n 


-MKtafl---- 

-  J5JI5't 0.002 " -  4/$<^3      " 

2n_d     Draw      , 
7ZWZ.  .S7ZZZ,  Finishfgt0.00£  Harden 
FIG.  130,  OP.  7 


BOLT 
(MarpStee/) 


*  I  i*^ 
-  _,««,  I  m%arrf 

m%325"-^-3.25^-3.2£-"-^-3.25"-^3.25"^-3.25'-'^ 

- /55? - .>i    FinishJgtaO0£"Handen 

/£?7^<- J    /0.a2£sxO.S"SfeeiPinsSncff 

tteadinq      Punch 
TOOL' STEEL 
,,    FIG,  137.  OR  20 

- 10.25 1 -0.002"--- >, 

-V»*-  £44-"-   »--0./25ff  I 


/6.5" 

Heading 
TOOL  STEEL,  fihishfgtClOO£ Harden 
FIG.  134,  OP.  20 


finish/too/" 
Shrink  on  Die 


\*mf  v%505fmoo:;^ 

^.-.^--/ff/y'-.-JOOr 

31d.Draw     „ 
TOOL  STEEL,  finish fgtO.005  Harden 

FIG.I3(.0RII 


Tapering 
TOOL  STEEL,rinishfgt0.O05"Harden 
FIG.I35.0P25 


f<  \<-- 4.95"- +0.000" -^ 
U.-..g24"-—^^-----^U 
4th    Dra 


/;' 


0.05 A       ^^-4.s9f+o.oa)^-o   ht 

(<. SL^^t.-JOO/Z J$§ 

r        R^1   Draw 
TOOL  STEEL,  finish/gfOOOS/faidea  ' 
FIG.  132,  OR  14  FIG.I33,0P.f7 


[89] 


Stamp  Lot  N° 
:  of  Ammunition 


ai'Tap 
M'Deep 


Stamp  Name  and  Model  of  Gun, 
Place  and  Yearof  Manufacture. 
Letters  and  Figures  OM'Deep 


„     i<- -075'- ->it« 

45Th reads  per  St** 

lnch,US.Std.    bmss,±QW5' 

Screw  Eye             Cartridge  Case  IZIb.  Solder  with  soft  Solder. 

Charge  L9JL  Tear  otf  after  Assembling 

Total  41  lb.  /  in  Cartridge  Case 


X-  ffoLgA  forec/  0.37$" Diam. 
Mandreled  to  0.41  "Diam. 
Finish  Bore  Taper  0.4698" 
at  large  End. 
Taper  0.002' in  Diam.  per 
Inch  in  Length 


CARTRIDGE  BRASS 

Cartridge  Case 


Total  Length  ?2J6'iW'- 


jji 

|!  i  Solder  with 
i^soff  Solder 

\<--3.5"W3--> 


** 


FIG.  136 


Composition  of  soft  Solder 
3  Parts  Lead,  3 Parts  Tin, 
I  Part  Bismuth 


SHEET  BRASS.0.01" Thick 
Diaphragm 


Diaphragm  to  press 
/against  Charge  Bag 


Stamp  Home  and  Model 
of  Howitzer  and  Place  and 
Yearof  Manufacture.  Letters 
>nd Figures  QOc'Deep 

'Solid  braided  white 
Cotton  Cord  Ne3i       n"/. 
DipinhoiParaffine    1 


S*.«mp  Lot  N*  of  Y-.'^T 

e..  [Ammunition  QOZ  Seep  *\\ 


li        0.615 


Flat  MACH.STEEL  „„  -     „  'W05 

Filisterhead     U- — I?'- finish /tt'vf    .       »      *        „       Cartridge  Case  .         , 

■M'Approx*  Harden      Std.Screw\y^  „,    * JCup  Plate    I  § ;  ^  mkt  Jfanrihrdtn*  n5",  30°        h ly "  ±0^ -, H 

tf3^«k£*rfc L **«3gif&%  y^^&WW^  i^r-> 7,0'"'~jl^. 

<5r  ,.?y.K-->«    *8S  ne?n»m-:    '■«     Ik- y/,r z.- hO->i  V  :v  •&■  5*  i_    /fflwl?~  t  usS_.» '•* h  .*'    ■  r  5?       srrrrrA — rsSz : 5s r*//siA 


■J/75V375*«-J^*>(^k 
K-55'-»k-5'-- 


IKtt, 


Ml   k- 
Cupping     £ ""_; '■■■■■  i4"i 


-,— *       ^1/75^375  m*^MZ?'^5.575'*I 


-I-i/ 


K— 55  ->t<- 
0625'Dhll 


•tf- 


k- aw» ^^ 

5+-h  Draw 
FIG.  155 


Jt  ^ 


,  *\4"Apprmf  Harden 

3"; 


\<— -■■■■■  13.94- 
I*  Draw 
FIG.I5I 


■>4/75l'375'»f--55r->t< ---  -^--•></5t<-  § 
"■«  -55"-->^ 13- >t    ht,  _ 

6  -  Draw 

FIG.  156 

f< 16.5"- H  , 

0.625  Drill    |  K ki;'a~^.u~~i~~. J 


^  -^175^ 575" ^2.65 -l 
t<-55"->* -5* 


-1  ^T~i^\-    M 


f 


WTR. 

2n-d  Draw 
FIG.  152 


*  ^|;75V-3.75-+- 
K-5.^-^ 


-  75?--4c- 1S""-M^-{).5"R.  7*  Draw 

FIG.  157 
-#.375"--- 


"\5Apprm.\*  Harden 
±-rr-JLuQfiZL, 


■•, - ■12.5'tBOOZ'—-^ 

r* -75'—  -"— - „-H 

|h^v-v-7^y-^_^ 


*  I  .  USStandard  • '    ftS  d  'H0^5 


*i  /75^  3  75M25f5>337/> 


—    ,^J/;,         -  ■» 

I  6Threads  per  Inch.  ^fc  h-0.875' 

15.5"- 

4 


l°S'i,%  WW5> 


■m"R. 

3  "^  Draw 
FIG.  153 


**l  lApprox.Hankrf' 
-x  !f-flgy'       -»i  K(?55' 


- -//iWf----H 

t<—  7.3" r-H 


Bolt--''"t37^/7/^54&r^^;^x-HeadPlug 
mcHSTta^- ^--^- _■■-- iam"-u--~>\     m%. 

Finish  f+/)0l         ,„  Heading  Punch ' "' vj % 


..j       Ring 

MACHSTEELFinish/tSOl' 

Shrink  on  Die 


r-ffl 
he 


i--r--l.;^ 


FIG.I59 

Tapering 


r  I     l» 

^->J/.75l--37/Hi375K-^^'4\#^ 

I Deec 4-  Draw 


r ^j|?5"  -- 

»•-- #'-  — 

Heading 
FIG.I58 

iStamp  Name  of  Cartridge  Case,  Operation,  Place  of  Manufacture  and  Date  (Year)  on  each  Punch 
•and Die  Fit  all  Shanks  to  Taper  Gage.  All  Threads  5 per  Inch,  U.S.  Std.  Pound  off  shtrp, 
Comer  on  all  Dies. 


[90] 


Cartridge  Case  for  6-Ix.  Howitzer,  Models  of 

1906  and  1908 

operation  1.   cupping 

Details  of  Cartridge  Case — Fig.  149.  Punch  and  Die — Fig. 
150.  Pressure — 75  tons.  Dimensions  of  Disk — Maximum 
diameter,  9.680  in.;  minimum  diameter,  9.675  in.;  maximum 
thickness,  0.405  in.;  minimum  thickness,  0.395  in.;  weight, 
9.0524  lb. 

SUCCEEDING  OPERATIONS 
Operation 

2  "Wash   and    anneal 

3  Pickle    and    wash 

4  First    draw;    punch    and    die,    Fig.    151;    pressure,    50 
tons 

5  Wash  and  anneal 

6  Pickle   and   wash 

7  Second   draw;   punch   and   die,    Fig.    152;    pressure,    45 
tons 

8  Wash  and  anneal 

9  Pickle  and  wash 


10  Third   draw;    punch    and    die,    Fig.    153;    pressure,    35 
tons 

11  Wash  and  anneal 

12  Pickle  and  wash 

13  Fourth   draw;    punch   and   die,    Fig.    154;   pressure,    30 
tons 

14  Wash  and  anneal 

15  Pickle  and  wash 

16  Fifth    draw;    punch    and    die,    Fig.    155;    pressure,    25 
tons 

17  Fifth-draw   trim;   trim   50   per   cent. 

18  Wash  and  anneal 

19  Pickle  and  wash 

20  Sixth    draw;    punch    and    die,    Fig.    156;    pressure,    25 
tons 

21  Sixth-draw  trim 

22  Wash  and  anneal 

23  Pickle   and   wash 

24  Seventh  draw;   punch  and   die.   Fig.   157;   pressure,   15 
tons 

25  Seventh-draw  trim 

26  Wash  for  heading 

27  Heading;   die,  Fig.   158;   pressure,   1800   tons 


FIGS.  160  TO  165.    PREPARING  FOR  THE  LOADING  OF  THE  PROPELLING  CHARGE 
Fig.  160 — Polishing  the  mouth.     Fig.   161 — Inserting  primer.     Fig.   162 — Spot   drilling  for  tracer  mark.      Fig.    163 — Stamping- 
lot  number.     Fig.  164 — Weighing  and  putting  in  the  powder.     Fig.   165 — Inserting  the  diaphragm 


[91] 


28  Rough-turn  head   and  drill  primer  hole 

29  Broach 

30  Burr   out 

31  Point  anneal 

32  Taper;  die,  Fig.  159,  pressure,  40  tens 

33  Finish-turn   head 

34  Drill  for  screw-eyes 

35  Tap   for   screw-eyes 

36  Stamp;  pressure,  13  tons 

37  Final   trim 

38  Inspect 

Loading  the  Propelling  Charge  and  Assembling 
to  Projectile 

Like  the  various  drawing  and  other  operations  on  the 
cartridge  cases,  the  loading  of  the  propelling  charge  fol- 
lows pretty  closely  along  the  same  general  lines,  so  that 
only  one  size  will  be  followed  through.    In  this  particular 


case  the  powder  is  put  loose  into  the  case,  but  in  others, 
especially  in  the  howitzer  types,  the  powder  is  placed  in 
one  or  more  bags.  In  the  howitzer  these  bags  are  tied  in 
by  means  of  cords  run  through  screw-eyes  placed  inside 
of  the  head.  In  a  large  number  of  cases  the  assembling 
is  done  in  the  field  or  just  previous  to  actual  use.  This, 
however,  has  nothing  directly  to  do  with  the  manufac- 
turing or  machining  processes,  so  will  not  be  expanded 
upon  here.  The  example  chosen  to  illustrate  the  loading 
process  is  the  case  and  projectile  for  the  3-in.  field  gun, 
models  of  1902,  190-1  and  1905,  and  the  operations  are: 

1.  Polish  mouth 

2.  Insert   primer 

3.  Fill    color   groove 

3|.     Spot  for  tracer  paint  mark 


FIGS.  166  TO  171.    VARIOUS  ASSEMBLING,  SOLDERING  AND  TESTING  OPERATIONS 

Fig.  166 — Soldering  in  the  diaphragm.     Fig.  167 — Pressing  in  the    projectile.      Fig.    168— -Creasing    machine. 
Soldering  on  the  can  lid.     Fig.   170 — Testing  for  leaks.     Fie.  171 — Packed   in  boxes 


Fig.    169- 


[92] 


4.  Stamp  lot  number 

5.  Put  in  propelling  charge 

6.  Insert  diaphragm 

7.  Solder    in    diaphragm 

8.  Fill  crimping  grooves 

9.  Press  in  projectile 

10.  Crimp   and   drop   in   can 

11.  Solder   on   can    top 

12.  Test  and  solder  small  hole 

13.  Varnish  and  box 

The  mouth  of  the  case  is  polished  to  provide  a  clean 
bright  surface  for  the  soldering  in  of  the  retaining  dia- 
phragm. The  case  is  chucked  as  shown  in  Fig.  160.  As 
it  turns,  the  operator  holds  emery  cloth  so  as  to  polish 
out  the  mouth  back  for  several  inches.  Waste  on  the 
end  of  a  stick  is  also  used  to  wipe  the  surface  clean. 
Primers  are  inserted  by  means  of  a  small  hand  press,  as 
shown  in  Fig.  161.  They  are  carried  to  the  bench  on 
board  trays  holding  200  primers. 

All  cartridge  cases  intended  for  use  with  projectiles  hav- 
ing night  tracers  must  be  spotted  with  a  blunt-end  drill 
and  the  spot  filled  with  red  paint,  as  a  distinguishing 
mark.  The  spotting  of  the  head  is  done  as  shown  in  Fig. 
162.  The  case  is  held  in  a  guiding  fixture  and  fed  for- 
ward onto  the  drill  by  means  of  the  tailstock  spindle.  A 
stop  bolted  to  the  top  of  the  front  lathe  bearing  is  used 
to  gage  the  depth  of  the  spot. 

The  lot  number  is  stamped  in  a  hand  press,  as  shown 
in  Fig.  163.  The  order  of  some  of  these  minor  opera- 
tions is  occasionally  varied  according  to  changing  shop 
conditions,  but  this  is  not  important.  In  loading  the  pro- 
pelling charge  into  this  case,  the  required  amount  of  pow- 
der is  weighed  out  and  poured  into  it,  the  outfit  used  be- 
ing shown  in  Fig.164.  The  next  operation  after  pouring  in 
the  powder  is  the  pressing  in  of  the  diaphragm,  which  is 
done  with  the  handled  gaging  plug  illustrated  in  Fig.  165. 

In  getting  ready  to  solder  in  the  diaphragm  the  operator 
first  polishes  the  inside  edges  of  the  diaphragm  slightly 
with  emery  cloth  and  then  proceeds  to  solder  the  edges  to 
the  case,  using  ordinary  soldering  coppers  heated  in  a 
bench  furnace  as  shown  in  Fig.  166. 

Following  the  work  on  the  diaphragm,  the  projectile 
is  pressed  in,  as  shown  in  Fig.  167,  and  then  the  case  is 
crimped  into  the  grooves  at  the  base  of  the  projectile,' 
using  the  machine  shown  in  Fig.  168.  Continuous  creases 
all  around  .are  not  produced,  but  indentations  like  those 
at  A  are  made.  After  crimping,  the  assembly  is  thrust 
into  the  gaging  chamber  B  and  then  dropped  into  a  tin 
can. 

The  can  cover  is  next  put  on  and  soldered  in  place  in 
the  bench  fixture,  Fig.  169.  The  can  is  tested  for  leaks 
with  the  device  illustrated  in  Fig.  170;  and  after  varnish 
has  been  applied  wherever  the  can  has  not  been  coated, 
it  is  ready  for  packing  in  boxes,  shown  in  Fig.  171.  Of 
this  size,  four  cans  are  packed  in  each  box.  The  boxes 
are  then  covered  and  nailed  ready  for  shipment. 

Loading  3-In.  Cartridge  Case  and  Assembling 
to  Projectile  for  Field  Gun 


OPERATION  1.  POLISH  MOUTH 
Machine  Used — Lathe,  Fig.  160.  Number  of  Operators  per 
Machine — One.  Work-Holding  Devices — Chuck;  work  runs  at 
475  ft.  surface  speed.  Production — 800  per  day.  Note — No.  2 
emery  cloth  is  used,  and  workman  presses  it  inside  of  mouth 
to  polish  for  soldering  in  diaphragm. 

OPERATION    2.    INSERT    PRIMER 
Machine    Used — Small    hand    press,    Fig.    161.      Number    of 
Operators  per  Machine — One.     Production — 1850   per  day. 

OPERATION  3.  FILL  COLOR  GROOVE 
Number  of  Operators — One.  Description  of  Operation — 
Operator  sets  case  on  end  and  applies  paint  to  the  circular 
groove  in  the  head.  Apparatus  and  Equipment  Used — Small 
round  brush  and  can  of  paint.  Production — 2000  per  day. 
Note — Colors:  Red  for  high  explosives,  yellow  for  shrapnel 
and  black  for  shell. 

OPERATION  3  J.  SPOT  FOR  TRACER  PAINT  MARK 
Machine  Used — Lathe,  Fig.  162.  Cutting  Tools — Blunt-point 
|-in.  gun  drill.  Cut  Data — Spindle  runs  600  r.p.m.  Production 
— 200  per  hr.  Note — Ten  per  cent,  of  the  cases  are  drilled 
just  enough  to  hold  a  dab  of  red  paint  to  identify  those 
carrying  night  tracers. 

OPERATION    4.    STAMP   LOT    NUMBER 
Machine    Used — Hand    press,    Fig.    163.  '    Production — 1700 
per  day. 

.  OPERATION  5.  PUT  IN  PROPELLING  CHARGE 
Number  of  Operators — One.  Description  of  Operation — 
Operator  weighs  and  pours  charge  of  smokeless  powder  into 
each  cartridge  case,  the  amounts  being  10,336  gr.  for  3-in. 
shrapnel  and  10,910  gr.  for  3-in.  common  shell  for  field  guns. 
Apparatus  and  Equipment  Used- — Scale,  measure  and  funnel. 
Fig.  164.     Production — 950  per  day. 

OPERATION  6.    INSERT  DIAPHRAGM 
Number    of    Operators — One.       Apparatus    and     Equipment 
Used — Wooden    plug    inserting    tool,    Fig.    165.      Production. — 
110  per  hr.     Note — The  shoulder  on  tool  is  1  J§    in.  back  from 
the  end  of  the  plug. 

OPERATION  7.    SOLDER  IN  DIAPHRAGM 
Description      of      Operation — Operator      solders      edges      of 
diaphragm    to   the    inside    of   the   cartridge    case,    as   shown    in 
Fig.   166.     Production — 550  to  575  per  day. 

OPERATION  8.  FILLING  CRIMPING  GROOVES  OF 
PROJECTILE 
Description  of  Operation — Operator  brushes  a  mixture  of 
1  lb.  beeswax  to  3  lb.  of  tallow  into  the  crimping  grooves  at 
the  base  of  the  projectile;  this  forms  an  air-  and  moisture- 
proof  seal  as  the  projectile  is  pressed  into  the  cartridge  case. 
Note — Operations  8,  9  and  10  are  done  by  two  men,  with  an 
output  of   875   per  day. 

OPERATION  9.  PRESSING  IN  PROJECTILE 
Description  of  Operation — Operator  places  case  in  the  hold- 
ing fixture,  sets  a  projectile  in  place  and  presses  it  down  until 
the  end  of  the  case  contacts  with  the  copper  band,  as  shown 
in  Fig.  167.  Note — This  is  the  same  for  both  the  3-in.  common 
and  the  3-in.  shrapnel   shell. 

OPERATION  10.  CRIMP  AND  DROP  IN  CAN 
Description  of  Operation — The  crimping  machine,  Fig.  168, 
does  not  crimp  continuous  grooves  all  around  the  case,  but 
makes  eight  indentations,  staggered  as  shown  at  A;  after 
crimping,  the  shell  is  thrust  into  the  cylinder  gage  B,  which 
is  the  same  size  as  the  chamber  of  the  gun;  the  operator  next 
drops  the  shell  into  a  tin  can. 

OPERATION  11.    SOLDER   ON  CAN  TOP 
Description  of  Operation — Operator  puts  lid  on  top  of  can 
and  places  it  on  the  rollers  of  the  fixture  shown  in  Fig.   169; 
he    then    securely    solders    the    edges    of    the    top    to    the    can. 
Production — 350   per  day. 

OPERATION  12.  TEST  AND  SOLDER  SMALL  HOLE 
Description  of  Operation — A  small  open  air  hole  has  been 
left  in  the  bottom  of  the  can;  the  operator  places  the  can 
bottom  up  and  thrusts  the  nozzle  of  an  air  hose  into  the  air 
hole,  as  shown  in  Fig.  170;  about  5  lb.  air  pressure  is  carried, 
and  the  air  valve  automatically  opens  as  the  nozzle  is  pressed 
to  the  can;  as  the  operator  presses  down  the  nozzle,  he 
watches  the  air  gage;  if  it  remains  stationary  the  can  is 
tight,  the  nozzle  is  removed  and  the  air  hole  soldered  up;  it 
the  can  leaks,  the  place  is  located  and  soldered.  Production — 
800  to  900  per  day. 

OPERATION  13.     VARNISHING  AND  BOXING 
Description  of  Operation — After  being  soldered,   the  can  is 
varnished    wherever    it    has    not    been    previously    coated,    and 
then  the  cans  are  placed  four  in  a  box,  as  shown  in  Fig.  171. 
Production — 1500  per  day. 


[93] 


INDEX 


(*  Indicates  Illustrations.) 


3-in.  Common  Shrapnel,  1-25 
Assembling: 

Balls,  compressing,  *  20,  21 
Case,  filling,  *  20,  21 

pinning  to  head,  22,  *  23,  *  24 

to  head,  22,  *  22 
Cosmoline,  brushing  on  fuse  threads,  24 

moistening  threads  of  head  and  case,  22, 
Cover,  crimping  on,  24,  25,  *  25 
Crimp  on  cover,  24,  25,  *  25 
Diaphragm  and  tube,  *  20,  21 
Grooving  for  waterproof  cover,  22,  24,  *  24 
Head,  pinning  to  case,  22,  *  23,  *  24 

to  case,  22,  *  22 
Lead  powder  charge,  *  18,  24,  *  25 
Lock  fuse,  24,  *  25 
Operation  sequence,  7 
Painting,  22.  23,  24,  *  25 

interior,  *  20,  21 
Resin,  cutting  out  surplus,  21,  *  21 
Screw  in  fuse,  24,  *  25 
Set  fuse  to  safety,  25,  *  25 
Tube  and  diaphragm,  *  20,  21 

inner,  inserting,  22,  *  22 
Turning  bourrelet,  *  7,  22,  *  23 
Wash  case  in  soda  water,  *  20.  21 
Balls  : 

Casting  ingots,  *  18,  19,  *  19,  20 
Compressing  in  assembly,  *  20,  21 
Extruding  wire,  *  18,  19,  *  19,  20 
Forming  on  punch  press,  18,  19,  *  19,  21 

on  special  machine,  *  18,  19,  *  19,  20 
Number  used,  1 
Operation  sequence,  7 
Rumbling,  *  18,  19,  21 
Size,  1,  *  19 
Weight,  6 
Band: 

See  also  under  "Common  Steel  Shell." 
Assembling,  5,  10 
Description,  25 
Turning,  *  2,  5,  *  10 
Weight,  6 
Case: 

Assembling  to  head,  22,  *  22 
Body,  turning,  *  2,  4,  *  4 
Bourrelet,  finishing,  4,  *  7 

turning,  *  7,  22,  *  23 
Centering,  *  2,  4,  *  4 
Dimensions,  *  1 
Filling,  *  20,  21 
Interior,  finishing,  *  2,  4,  *  7,  10 

painting,  *  20,  21 
Operation  sequence,  6 
Outside,  finishing,  *  2,  4,  *  5,  *  6,  7,  10 
Painting  exterior,  22,  23,  24,  *  25 
Pinning  to  head,  22,  *  23,  *  24 
Tapping  for  head,  *  2 

for  night  tracer,  5,  *  8 
Testing,  *  2,  5 
Washing,  *  20,  21 
Weight,  6 
Charge,  see  "Powder." 

Cover,  waterproof,  grooving  case  for,.  22,  24,  *  24 
Diaphragm  : 

Assembling  with  tube,  *  20,  21 

Base,  painting,  14,  *  15,  15 

Drill  and  counterbore,  14,  *  14,  15 


22 


Diaphragm  : — Continued 

Heat-treatment,  14 

Operation  sequence,  7 

Scale,  removing  from  counterbore,  14,  *  15,  15 

Tube,  assembling,  14,  *  15,  15 

Weight,  6 
Forgings: 

Chemical  tests,  1 

Dimensions,  *  1 

Phosphorus  content,  1 

Physical  tests,  1 

Sulphur  content,  1 

Testing,  6 

Tool  life  turning,  6 
Fuse: 

Assembling  to  case,  24,  *  25 

Description,  1 

Setting,  1 

to  safety,  25,  *  25 

Threads,  brushing  on  cosmoline,  24 

Weight,  6 
Head: 

Assembling  to  case,  22,  *  22 

Countersink,  *  9,  11,  12,  *  12 

Details,  *  10 

Locking  fuse  to,  12 

Machine,  *  9,  *  10,  *  11,  12 

Notches,  milling,  *  9,  12,  13,  *  13 

Operation  sequence,  6,  11 

Painting,  *  11,  12,  14 

Pinning  to  case,  22,  *  23,  *  24 

Production,  11 

Resin,  facing  off,  *  11,  12,  14 
filling,  see  "Head-retainer." 

Retainer,  insert  and  fill  with  resin,  *  9,  *  11,  12,  14 

Tapping  case  for,  *  2 

Thread,  turning,  11,  *  11,  13 

Washer,  crimp  in,  *  9,  *  13,  14 

Washing,  12,  14 

Weight,  6 
Head  Filler: 

Weight,  6 
Lathe  tools,  *  3 
Locking  Pins: 

Machining,  15,  *  15 
Matrix  : 

Weight,  6 
Paint,  proportions  of,  23 
Powder: 

Amount,  1 

Loading,  *  18,  24,  *  25 

Weight,  6 
Retainer: 

Machining,  17,  *  17 

Weight,  6 
Tools,  standard  lathe,  *  3,  10 
Tracer: 

Description,  6 

Making,  25;  see  also  "Common  steel  shell." 

Tapping  case  for,  5,  *  8 
Tube: 

Assembling  with  diaphragm,  14,  15,  *  15,  *  20,  21 

Central,  machining,  16,  *  16 

Inner,  machining,  16,  *  16 

Weight,  6 
Washer: 

Punching,  17,  *  17 

Weight,  6 


[95] 


3-in.  Common  Steel  Shell,  (High  Explosive),  26-47 
Band: 

See  also  "Band"  under  3-in.  Common  Shrapnel;  also  under 
"Case." 
Annealing,  43 

Assembling  to  case,  *  35,  *  36,  37 
Cutting  from  tubing,  *  42,  43 
Operations  in  machining,  47 
Pickling,  43 

Planishing,  *  40,  *  42,  43,  47 
Tools  used,  *  35,  43 
Turning,  *  35,  37,  *  37,  43 
Washing,  43 
Weight  of,  29 
Base  Cover: 

See  also  "Loading." 

Assembling  to  case,  *  40,  *  41,  41,  47 
Weight  of,  29 
Case: 

Band,  assembling,  *  35,  *  36,  37 
seat,  knurling,  *  31,  33,  34 

turning,  *  32,  33,  34 
turning,  *  35,  37,  *  37,  43 
Base  cover  groove,  finishing,  *  34,  *  36,  37 
roughing,  *  34,  35,  *  35,  37 
facing,  *  32,  33,  34 

finishing,  *  27,  *  29,  30,  *  30,  *  31,  *  32,  34 
notching,  *  27,  33,  *  34.  36 
rough  facing,  28,  *  28,  30 
Body,  finishing,  *  27,  33,  *  34,  36 

roughing,  *  27,  *  28,  *  29,  30 
Bourrelet,  roughing,  36 
Centering,  28,  *  29 
Counterboring,  34,  *  35,  38 
Gaging,  *  28,  30,  33 
Inspecting,  45 

Interior,  boring,  *  27,  *  32,  33,  36 
rough  boring,  34,  35,  *  35 
sand  blasting,  *  38,  38,  45 
Operations  on,  29 
Point,  finishing,  *  32,  33,  *  33 
roughing,  *  27,  28,  *  29,  36 
Tapping,  *  30,  33,  34 
Testing,  hydraulic,  *  36,  *  38,  39,  45 
Thread  shoulder,  *  29,  33,  37 
Threading,  *  31,  *  35,  43 
Threads,  resizing,  34,  *  35,  38 
Tools  used,  *  27,  *  29,  30 
Weight  of,  29 
Cover,  base,  see  "Loading." 
Details  of  complete  projectile,  *  26 
Detonator,  26 
Explosive,  see  "Loading." 
Forgings,  details  of,  *  26 
Fuse: 

Assembling  with  case,  40,  *  40,  *  41,  47 
Case,  reaming  hole  in  explosive  for,  40,  *  40,  *  41,  47 
Weight  of,  29 
Holding  devices  for  various  parts,  30,  36,  37 
Loading: 

Cover,  attaching  and  calking,  *  40,  *  41,  41,  47 
Explosive,  26 

compressing,  *  39,  40,  47 
filling  case  with,  39,  *  39 
nature  of,  46 

reaming  hole  in,  40,  *  40,  *  41,  47 
weight  of,  29 
Fuse,  screwing  into  place,  40,  *  40,  *  41,  47 
Operations  involved,  45 
Painting  exterior,  *  40,  40,  *  41,  47 

interior,  39,  *  39,  45 
Threads  and  counterbore,  cleaning,  40,  *  40,  *  41,  47 


Loading  '.—Continued 
Tools  for,  *  41,  47 

Tracer,  screwing  into  place,  41,  *  41,  47 
Weighing  case,  *  39,  39,  46 
Night  Tracer: 

Assembling  with  case,  41,  *  41,  47 
Counterboring,  drilling,  and  tapping,  43,  *  43 
Drilling,  counterboring,  and  tapping,  43,  *  43 
End,  facing  and  threading,  44,  *  44 

trimming,  46,  *  46 
Facing  end  and  threading,  44,  *  44 
Loading,  counterboring  powder,  46,  *  46 

ignition  mixture,  46,  *  46 

illuminating  powder,  46,  *  46 

operations,  *  46,  47 

retarding  mixture,  46,  *  46 
Operations  in  machining,  47 
Tapping,  drilling  and  counterboring,  43,  *  43 
Trimming  end,  46,  *  46 
Use  of,  26 
Night  Tracer  Disks: 

Ignition  tube,  assembling  to  outer  disk,  44,  *45 
Ignition  tubes,  milling,  44,  *  45 

turning, -44,  *  45 
Inner  disk,  punching,  44,  *  44 
Operations  on,  *  44,  *  45,  47 
Outer  disk,  assembling  to  ignition  tube,  44,  *  45 

punching,  44,  *  45 
Painting,  see  "Loading." 
Trinitrotoluol,  see  "Loading." 
Weight  of  various  parts,  29 

3-in.  United  States  Navy  Projectiles,  48-55 
Air  vents,  cutting  in  sinusoidal  ribs,  53,  *  53 
American  Car  &  Foundry  Co.,  48 
Band,  fitting,  53,  *  53 

roughing  and  finishing,  *  53,  54,  *  54 

score  and  base,  turning,  49,  *  49,  51 
cutting  sinusoidal  ribs  in,  52,  *  52,  *  53 
maintaining  position  of,  53 
Base  and  land  score,  turning,  49,  *  49,  *  51 

facing,  49,  *  49 

hole  in,  drilling,  48,  49 

marking,  *  50,  52 

reaming,  counterboring,  and  tapping,  *  53,  54 
Body,  finishing,  50,  *  50 

roughing,  50,  *  50,  *  51 
Bourrelet,  finishing,  50,  *  50 
Carriage,  special  for  roughing  body,  50 
Centering,  48,  *  49 
Centers,  drilling,  48,  *  49 
Cuts,  drilling  base,  49 

turning  base,  49 
'  facing  base,  50 

roughing  band  score,  50 

finishing  band  score,  50 

roughing  body,  50 

finishing  body  and  bourrelet,  50 

roughing  and  finishing  point,  51 

cutting  sinusoidal  ribs,  53 

turning  band,  54 
Dimensions  of  projectile,  *  48 
Eccentricity,  testing  forging  for,  49,  *  49 
Facing  base,  49,  *  49,  50 
Feeds,  drilling  base,  49 

turning  base,  49 

facing  base,  50 

roughing  band  score,  50 

finishing  band  score,  '50 

roughing  body,  50 

finishing  body  and  bourrelet,  50 

roughing  and  finishing  point,  51 


[96] 


Feeds,  cutting  sinusoidal  ribs,  53 

turning  band,  54 

counterboring  fuse  hole,  54 
Forgings,  details  of,  *  48,  *  51 

distortion  of,  49 

testing  for  eccentricity,  49,  *  49 
Fuse  hole,  reaming,  counterboring  and  tapping,  *  53,  54 
Gaging,  *  50,  52,  52 

for  facing  base,  50,  *  50 
Holding  projectile,  methods  of,  48,  49,  *  49,  50,   *  50,  51,  52, 

*  52,  53,  54 
Hole  for  fuse,  reaming,  counterboring  and  tapping,  *  53,  54 
Hole  in  base,  drilling,  48,  49 
Interior,  lacquering,  *  54,  55 

washing,  *  54,  55 
Lacquering  interior,  *  54,  55 
Loading,  55 
Lubricants,  drilling  base,  49 

turning  base  and  band  score,  49 

finishing  band  score,  50 

finishing  body  and  bourrelet,  50 

roughing  and  finishing  point,  51 

cutting  sinusoidal  ribs,  53 

turning  band,  54 

tapping  fuse  hole,  54  \ 

Machines,  type  necessary,  48 
Marking  base,  *  50,  52 
Painting,  55 
Point,  finishing,  50,  *  50,  *  51 

roughing,  50,  *  50,  *  51 
Pressure  for  landing,  54 
Sinusoidal  ribs,  cutting,  52,  *  52,  *  53 

cutting  air  vents  in,  53,  *  53 
Speeds,  drilling  base,  49 

turning  base,  49 

finishing  band  score,  50 

roughing  body,  50 

finishing  body  and  bourrelet,  50 

roughing  and  finishing  point,  5l 

cutting  sinusoidal  ribs,  53 

turning  band,  54 

counterboring  fuse  hole,  54 

tapping  fuse  hole,  54 
Testing,  50,  52,  *  52 
Tools,  turning  band  score  and  base,  49,  *  49,  *  50 

turning  point,  *  50,  51 

turning  sinusoidal  ribs,  52,  *  53,  53 

turning  band,  *  53,  54 

reaming,  counterboring  and  tapping  base.  54 
Washing,  *  54,  55 
Weighing,  52,  *  52 

3.8,  4.7  and  6  in.  Common  Shrapnel  and  High  Explosive  Shells, 

56-61 
3.8-in.  Common  Shrapnel  (30  lb.),  56 
Band,  see  "Case." 
Case  : 

Band,  assembling  with  case,  56 

turning,  50 
Body,  turning,  56 
Bourrelet,  finishing,  56 

roughing,  56 
Centering,  56 

Dimensions,  finished,  56,  *  56 
Exterior,  finishing,  56 
Head,  assembling,  56 
disassembling,  56 
finishing,  56 
Hydraulic  test  of,  56 
Interior,  finishing,  56 
Ogive,  roughing,  56 
Painting  interior,  56 


[97] 


Case: — Cordinued  ■     ;     •  \ •.••••»  l":*\  • 

Washing,  56  . . ' •  "     '•■*.?'•?■  *a 

Diaphragm,  operations  on,  58 
Forging,  details  of,  56,  *  56 
Head: 

Countersinking,  58 

Filling,  58 

Grooving  for  cover,  58 

Inspect,  58 

Machining  from  bar,  58 

Notches,  milling,  5S 

Painting  inside,  58 

Pin  to  case,  58 

Reassemble  to  case,  58 

Resin,  cut  out  surplus,  58 

Retainer,  placing,  58 

Threading,  58 

Threads,  coating  with  cosmoline,  58 

Tube,  insert,  58 

Washer,  crimping,  58 
Loading  operations,  58 
Locking  pins,  machining,  58 
Projectile,  details  of  complete,  56,  *  56 
Retainer,  machining,  58 
Tube: 

Central,  machining,  58 

Inner,  machining,  58 
inserting  in  head,  58 
Washer: 

Crimping,  58 

Punch,  58 

4.7-in.  Common  Shrapnel  (60  lb.),  *  57,  58 
6-in.  Common  Shrapnel  (120  lb.),  *  57,  *  58,  59 
3.8-in.  Common  Steel  Shell  Model  1905,  59,  *  59 
4.7-in.  Common  Steel  Shell  Model  1905,  59 
Band: 

Assembling  with  case,  59 
Turning,  59 
Base  Plug: 

Machine  from  bar,  59 
Notching  base,  61 

Thread,  external,  cutting  on  lathe,  59 
external,  milling,  61 
internal,  milling,  59 
Wrench  slots,  milling,  61 
Case: 

Band,  assembling  with  case,  59 

turning,  59 
Base  cover  grooves,  machining,  59 

machining  interior  and  exterior,  59 
Body,  finishing,  59 

roughing,  59 
Bourrelet,  finish  grinding,  59 

roughing,  59 
Dimensions  of,  59,  *  60 
Heat  treating,  59 
Hydraulic  test,  59 
Point,  finishing,  59 
Threads  in  base,  milling,  59 
Forging,  dimensions  of,  59,  *  60 

6-in.  Common  Steel  Shell,  61      . 
6-in.  Naval  Shells,  62-70 
Band,  cutting  grooves  in,  68 

finishing,  68 

score,  65 
Banding,  *  65,  66 
Base,  counterboring,  68 

marking,  *  65,  67 

plugs,  installing,  69,  *  69,  *  70 
machining,  69 


V 


I 


Base,  plugs  mnnboi-mg,  (V> 

rounding,  65 

threading,  68,  *  68 
Boring  heads  and  bars  for  interior,  *  64,  65 
Bourrelet,  finishing,  68 
Cavity,  see  "Interior." 
Center  of  gravity,  62 
Centering  forgings,  63,  *  63 
Centers,  drilling  in  forging,  *  63,  64 
Chucks  for  holding  shells,  62 
Concentricity,  62 
Cost  of  equipping  machines,  69 
Cost  of  shells,  69 
Counterboring  base,  68 
Cuts,  roughing  body,  65 

roughing  and  finishing  interior,  65 
Eccentricity,  gaging  for,  *  66,  67 
Essentials  of  machining,  62 
Feeds,  roughing  body,  65 

finishing  outside,  68 
Finishing  outside,  *  66,  67,  *  67 
Forgings,  centering,  63,  *  63 

details  of,  *  62,  65 

setting  correctly  for  turning  outside,  64 
Gaging,  63,  *  63,  64,  *  66,  67,  *  67,  68 
Groove  at  rear  of  band,  cutting,  68 

Holding  projectiles,  methods  of,  62,  64,  65,  66,  67,  68,  69 
Interior,  boring,  65 

lacquering,  69,  *  70 
Lacquering  interior,  69,  *  70 
Lubricant,  turning  body,  65 

boring  interior,  65 

finishing  outside,  68 
Machines,  methods  of  setting-up,  62 
Marking  size  before  finishing,  *  66,  67 
Outside,  finishing,  *  66,  67,  *  67 

rough  turning,  *  63,  64,  *  64 
Painting,  69,  *  70 
Plugs,  installing  base,  69,  *  69,  *  70 

machining  base,  69 

numbering  base,  69 
Pressure  applied  in  banding,  67 
Radius,  finishing,  68 

turning  attachment,  *  63,  64 
Sinusoidal  ribs,  *  64,  65 

cutting  air  vents  in,  *  64,  66 
Size,  marking  before  finishing,   *  66,  67 
Speeds,  roughing  body,  65 

roughing  and  finishing  interior,  65 
finishing  outside,  68 
Threading  base,  68,  *  68 
Tongs  for  handling  shells,  69,  *  69 
Tools,  for  turning  outside  of  body,  64,  65 

for  boring  interior,  *  64,  65 

rounding  base,  cutting  band  score  and  sinusoidal  ribs,  65 

finishing  outside,  68 
Washing,  69,  *  69,  *  70 
Weighing,  *  66,  67,  *  67,  68,  69 
Weight,  62 


Diaphragm  : — Continued 

Blanking,  81,  *  82 

Details  of,  72,  *  72 

Forming,  81,  *  82 

Operation  sequence,  80 

Piercing,  81,  *  82 

Solder  to  tracer  tube,  81 
Drawing,  *  72,  *  73,  *  74,  *  75,  76,  *  76 
Finish  trim,  78,  *  78,  *  80 
Head,  finishing,  *  76,  77,  *  78;  *  79 

roughing,  *  75,  76 
Heading,  *  72,  75,  *  75,  *  76 
Inspecting,  78,  *  79,  *  80,  *  81 
Loading  and  Assembling  to  Projectile: 

Can,  placing  in,  *  92,  93 
soldering  test  hole,  *  92,  93 
soldering  top,  *  92,  93 
testing  for  leaks,  *  92,  93 

Charge,  nature  of,  92 
placing,  *  91,  93 

Color  groove,  filling,  93 

Crimping,  *  92,  93 
grooves,  filling,  93 

Diaphragm,  inserting,  *  91,  93 
soldering,  *  92,  93 

Mouth,  polishing,  *  91,  93 

Number,  stamping,  *  91,  93 

Operation  sequence,  92 

Projectile,  pressing  in,  *  92,  93 

Primer,  inserting,  *  91,  93 

Spot  for  tracer  point  mark,  *  91,  93 
Operation  sequence,  73 
Ordnance  department  specifications,  71 
Pickle  and  wash,  72,  *  73,  74,  75,  76 
Point  annealing,  77,  *  78 
Primer: 

Hole  for,  broaching,  76,  *  77 
burring,  *  75,  77,  *  77 
drilling,  *  75,  76 
punching,  *  72,  *  75,  *  76,  77 

Position  of,  72,  *  72 
Specifications,  71 

Stamping  head,  *  72,  77,  *  78,  *  79 
Tapering,  77,  *  78,  *  79 
Tube  for  Tracer: 

Annealing,  81 

Assemble  with  diaphragm,  81 

Blanking,  81,  *  82 

Drawing,  81,  *  82,  *  83 

Operation  sequence,  80 

Pickling,  81 

Solder  to  diaphragm,  81 

Trimming,  81,  *  83 

Washing,  81 
Trim,  finish,  78,  *  78,  *  80 
Trimming,  *  72,  *  73,  *  74,  75,  77,  *  78,  *  80 
Wash  and  anneal,  72,  *  73,  74,  75,  76 
Wash  and  pickle,  72,  *  73,  74,  75,  76 
Washing  for  heading,  75 


3-  to  6-in.  Cartridge  Cases,  71-93 

3-in.  Field  Gun  Case,  Models  1902,  1904,  1905,  72-80 

Anneal  and  wash,  72,  *  73,  74,  75,  76 
Assembling  to  projectile,  see  "Loading." 
Broaching  primer  hole,  76,  *  77 
Cupping,  72,  *  72,  73,  *  73,  *  74 
Detailed  drawing,  72,  *72 
Diaphragm: 

Assemble  with  tube  for  tracer,  81 


3-in.  Mountain  Howitzer  Case,  Models  1907  and  1911,    *  80, 

81,  82,  *  84 
3-in.  Gun  Case,  15  Pounder,  Model  1898-1902,  82,  83,  *  85 
3-in.  Gun  Case,  15  Pounder,  Model  1903,  83,  *  86 
3.8-in.  Howitzer  Case,  Model  1908,  87,  *  87 
4.7-in.  Gun  Case,  Model  1906,  88,  *  88 

4.7-in.  Howitzer  Case,  Models  1907, 1908  and  1912,  88,  89,  *  89 
6-in.  Gun  Case,  *  90 
6-in.  Howitzer  Case,  Models  1906  and  1908,  *  90,  91 


[98] 


UNIVERSITY  OF  CALIFORNIA  LIBRARY 
BERKELEY 

Return  to  desk  from  which  borrowed 
This  book  is  DUE  on  the  hut  date  stamped  below. 


RETURN  TO  the  circulation  desk  of  any 

University  of  California  Library 

or  to  the 

NORTHERN  REGIONAL  LIBRARY  FACILITY 
Bldg.  400,  Richmond  Field  Station 
University  of  California 
Richmond,  CA  94804-4698 

ALL  BOOKS  MAY  BE  RECALLED  AFTER  7  DAYS 
2- month  loans  may  be  renewed  by  calling 

(510)  642-6753 
1-year  loans  may  be  recharged  by  bringing  books 

to  NRLF 
Renewals    and    recharges    may    be    made    4    days 

prior  to  due  date 

DUE  AS  STAMPED  BELOW 

MM  3  0  TO 


20,000  (4/94) 


&  00357 


36  id  58 


[]  A^A 


UNIVERSITY  OF  CALIFORNIA  LIBRARY 


